Aeb16e1 01

.
FOREWORD
1-1
.
FOREWORD FOREWORD
FOREWORD
This manual provides rules and guidelines which will help you use this lift truck safely and effectively. Always be sure
to read and understand this manual thoroughly before operating and performing maintenance.
Some actions involved in operation and maintenance of the lift truck can cause a serious accident if they are not
done in the manner described in this manual.
WARNING
Improper operation and maintenance of this lift truck can be hazardous and could result in serious injury or death.
Operators and maintenance personnel should read this manual thoroughly before beginning operation or maintenance.
Keep this manual handy and have all personnel read it periodically.
Do not use this lift truck unless you are sure that you have understood the contents completely.
If this manual has been lost or has become dirty or worn and cannot be read, request a replacement manual from your Komatsu
Forklift distributor/dealer.
Komatsu Forklift delivers lift trucks that comply with (to the best of our knowledge at the time of delivery) all applicable
regulations and standards of the country to which they have been shipped.If this lift truck has been purchased in another
country or purchased from someone in another country, it may lack certain safety devices and specifications that are
necessary for use in your country. If there is any question about whether your product complies with the applicable standards
and regulations of your country, consult your Komatsu Forklift distributor/dealer before operating the lift truck.
Continuing improvements in the design of this lift truck may not be reflected in this manual.Consult Komatsu Forklift or your
Komatsu Forklift distributor/dealer for the latest available information on your lift truck or for questions regarding information
in this manual.
Information on safety is given in SAFETY INFORMATION (PAGE 1-3) and SAFETY (PAGE 2-1).
1-2
.
FOREWORD SAFETY INFORMATION
SAFETY INFORMATION
Most accidents are caused by a failure to follow fundamental safety rules for the operation and maintenance of lift
trucks.
To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the lift truck
before operating and performing maintenance.
Do not operate or carry out maintenance of this lift truck unless you are sure that you understand the explanations
and procedures completely.
To identify safety messages in this manual and on lift truck labels, the following signal words are used.
These safety messages or labels describe precautions that must be taken to avoid a hazard
which carries a serious risk of serious injury or death.
These safety messages or labels usually describe precautions that must be taken to avoid
a hazard which may lead to serious injury or death.
This word is used on safety messages and safety labels for hazards which could result in
injury or damage to the lift truck or surrounding property if the hazard is not avoided.
This word is used for precautions that may not lead to damage or failure, but which must be
taken to avoid actions that could shorten the life of the lift truck.
Safety precautions are described in SAFETY (PAGE 2-1).
Komatsu Forklift cannot predict every circumstance that might involve a potential hazard in operation and
maintenance. Therefore the safety messages in this manual and on the lift truck may not include all possible safety
precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility
to be sure that you and others can do such procedures and actions safely and without damaging the lift truck. If you
are unsure about the safety of some procedures, contact your Komatsu Forklift distributor/dealer.
The procedures and precautions given in this manual apply only to intended uses of the lift truck. If you use your lift
truck for any unintended use that is not specifically prohibited, you must be sure that it is safe for you and others.
In no event should you or others engage in prohibited uses or actions as described in this manual.
1-3
.
DIRECTION OF TRUCK FOREWORD
DIRECTION OF TRUCK
This manual determines the left and right directions and fore and aft directions as seen from the operator's seat.
1-4
.
FOREWORD WARRANTY AND SERVICE FOR NEW LIFT TRUCK
WARRANTY AND SERVICE FOR NEW LIFT TRUCK

KOMATSU FORKLIFT GENUINE PARTS
Komatsu Forklift genuine parts are manufactured from the same materials and by the same method as the parts built
in the new lift truck.
In the event that the customer uses imitation parts, Komatsu Forklift will not be held accountable for any faults which
result from the use of such imitation parts, and the Komatsu Forklift warranty will not be applicable.
Always use Komatsu forklift genuine parts when replacing parts.
1-5
.
RUNNING IN NEW LIFT TRUCK FOREWORD
RUNNING IN NEW LIFT TRUCK

RUNNING IN NEW LIFT TRUCK
Your Komatsu Forklift truck has been thoroughly adjusted and tested before shipment.
However, operating the lift truck under severe conditions at the beginning can adversely affect performance and
shorten the lift truck life. Be sure to run in the lift truck, taking special care concerning the following items.
Idle the engine for 5 minutes after starting it up.
Avoid operation with heavy loads or at high speeds.
Avoid sudden starting or acceleration, unnecessarily abrupt braking and sharp turning, except in the case of
emergency.
FIRST MONTH SERVICE (OR INITIAL 200 HOURS SERVICE) FOR NEW LIFT TRUCK
For new lift truck, carry out the following maintenance only after the first month or 200 hours.
Unit Check items Remarks

Change oil
Engine Replace oil filter element
Drain water from fuel filter Diesel engine lift truck only
Change oil
TORQFLOW transmission } TORQFLOW lift truck only
Clean strainer
Differential Change oil
Change oil
Replace line filter
Hydraulic tank
Clean strainer
Clean inside tank
Particularly hub nuts, overhead guard
Other Tighten all bolts and nuts mounting bolts, backrest mounting bolts,
and operator's seat mounting bolts.
1-6
.
FOREWORD LOCATION OF PLATES
LOCATION OF PLATES
APPLICABLE LIFT TRUCK SERIAL NO.
Model Applicable lift truck Model Applicable lift truck
FG10/15/18-20 M220-650001 and up FD10/15/18-20 M223-650001 and up
FG15H/18H-20 M221-650001 and up
FG20/25-16 M225-700001 and up FD20/25-16 M228-700001 and up
FG30/35A-16 M226-700001 and up FD30-16 M229-700001 and up
FG20H/25H-16 M227-700001 and up FD20H/25H-16 M230-700001 and up
FG20N/25N-16 M232-700001 and up FD30H/35A-16 M231-700001 and up
FG30N-16 M233-700001 and up FD20N/25N-16 M234-700001 and up
FD30N-16 M235-700001 and up
APPLICABLE LIFT TRUCK SERIAL NO. LOCATION

LIFT TRUCK SERIAL NO. PLATE POSITION
It is on the upper right side of the dashboard.
LIFT TRUCK EMBOSSED SERIAL NO. LOCATION

It is stamped on top of the front fender on the left side of the lift
truck.
1-7
.
LOCATION OF PLATES FOREWORD
EMBOSSED SERIAL NO. LOCATION

The engine serial number is stamped in the position shown below.
(Left) and (Right) in the diagram are as follows.
(Left): Left side of engine, (Right): Right side of engine.
Gasoline engine
K15/K21/K25
Diesel engine
4D92E/4D94LE/4D98E
APPLICABLE LIFT TRUCK SERIAL NO.

(1) Model
(2) Serial No.
(3) Year/ Month of manufacture
(4) Unladen mass
(5) Actual capacity
(6) Load center
(7) Capacity
(8) Load center
(9) Max. fork height
(10) Attachment model
(11) Front/ Rear tire size
(12) Front/ Rear tire inflation pressure
(13) Tread. Front
(14) Tilting angle backward
For how to read the load capacity chart (in relation to (5) through (10) above), see the section of SAFETY, (LOAD
CENTER AND ACTUAL CAPACITY (PAGE 2-29)).
A nameplate for lift trucks of the US specifications differs from the one shown above in the shape.
1-8
.
FOREWORD CONTENTS
CONTENTS
FOREWORD 1- 1
FOREWORD 1- 2
SAFETY INFORMATION 1- 3
DIRECTION OF TRUCK 1- 4
WARRANTY AND SERVICE FOR NEW LIFT TRUCK 1- 5
KOMATSU FORKLIFT GENUINE PARTS 1- 5
RUNNING IN NEW LIFT TRUCK 1- 6
FIRST MONTH SERVICE (OR INITIAL 200 HOURS SERVICE) FOR NEW LIFT TRUCK 1- 6
LOCATION OF PLATES 1- 7
APPLICABLE LIFT TRUCK SERIAL NO. 1- 7
APPLICABLE LIFT TRUCK SERIAL NO. LOCATION 1- 7
EMBOSSED SERIAL NO. LOCATION 1- 8
SAFETY 2- 1
SAFETY MANAGEMENT 2- 2
SAFE TRAVEL 2- 5
LOADING OPERATIONS 2- 15
SAFETY IN PERIODIC MAINTENANCE 2- 20
STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM
TIPPING!) 2- 26
SAFETY LABEL STICKING POSITIONS 2- 31
INTRODUCTION OF OPTIONAL EQUIPMENT 2- 36
TOWING 2- 37
OPERATION 3- 1
GENERAL VIEW 3- 2
GENERAL VIEW OF LIFT TRUCK 3- 2
INSTRUMENTS AND CONTROLS 3- 3
EXPLANATION OF COMPONENTS 3- 5
METER PANEL 3- 5
REMOVING AND INSTALLATION OF ATTACHMENTS 3- 10
OPERATION 3- 13
MOUNTING/DISMOUNTING 3- 13
SEAT POSITION ADJUSTMENT 3- 13
ADJUSTING POSITION OF STEERING WHEEL 3- 15
STARTING LIFT TRUCK OFF 3- 16
STARTING AND INCHING ON INCLINE 3- 22
TURNING 3- 23
TEMPORARY STOPPING AND PARKING 3- 24
FORK SPREAD ADJUSTMENT 3- 25
LOAD HANDLING OPERATION 3- 26
COMBINATION SWITCH OPERATION 3- 28
COLD WEATHER OPERATION 3- 29
PREPARATIONS FOR LOW TEMPERATURE 3- 29
PRECAUTIONS AFTER COMPLETION OF OPERATIONS 3- 30
ACTIONS IN ENGINE OVERHEATING 3- 31
LONG-TERM STORAGE 3- 32
BEFORE STORAGE 3- 32
1-9
.
CONTENTS FOREWORD
DURING STORAGE 3- 32
AFTER STORAGE 3- 32
TRANSPORTATION 3- 33
MAINTENANCE 4- 1
CHECK BEFORE OPERATION 4- 2
CHECK BEFORE OPERATION (WITH KEY SWITCH OFF) 4- 2
CHECK AFTER STARTING (WITH STARTING SWITCH ON) 4- 8
CHECK WHILE ADVANCING SLOWLY 4- 12
CHECK OF WORK EQUIPMENT OPERATION 4- 12
CHECK AFTER OPERATION 4- 13
OUTLINE OF SERVICE 4- 14
SUITABLE OIL 4- 14
LUBRICANT LIST 4- 16
OIL AND GREASING CHART (OIL, GREASE LOCATIONS AND INSPECTION AND
MAINTENANCE INTERVALS) 4- 16
LUBRICANT LIST 4- 17
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4- 18
MAINTENANCE 4- 19
MAINTENANCE OF ENGINE 4- 19
CLEAN, REPLACE AIR CLEANER ELEMENT 4- 22
CHECK BATTERY ELECTROLYTE SPECIFIC GRAVITY 4- 23
CLEAN RADIATOR FINS, CHECK FOR DAMAGE 4- 24
CLEAN INSIDE OF COOLING SYSTEM 4- 24
CHANGE OIL IN DIFFERENTIAL CASE (FOR CLUTCH TYPE LIFT TRUCKS, INCLUDES
TRANSMISSION CASE) 4- 26
CHANGE OIL IN TORQFLOW TRANSMISSION CASE AND CLEAN STRAINER 4- 27
CHANGE HYDRAULIC OIL 4- 28
REPLACING TIRES 4- 29
REPLACING FUSES 4- 30
REPLACING LAMPS 4- 31
SERVICE DATA 4- 32
SERVICE DATA (GASOLINE ENGINE LIFT TRUCK) 4- 32
SERVICE DATA (DIESEL ENGINE LIFT TRUCK) 4- 35
TORQUE LIST 4- 37
TECHNICAL DATA 5- 1
TECHNICAL DATA 5- 2
INDEX 6- 1
1 - 10
.
SAFETY
2-1
.
SAFETY MANAGEMENT SAFETY
SAFETY MANAGEMENT
FOLLOW THE INSTRUCTIONS IN THE OPERATION AND MAINTENANCE MANUAL AS WELL AS IN THE SAFETY
LABELS
Read the instructions in this Manual and the safety labels attached to various parts of the lift truck, and make sure
that you understand and follow them. If you do not understand or do not follow the instructions, this will lead to
improper operation which may result in personal injury or damage.
Be sure that you understand the proper method of using the lift truck and the procedure for carrying out an
inspection, and ensure that they are carried out safely.
Read this Manual and safety labels again from time to time. If the Operation and Maintenance Manual or safety
labels have been lost or have become dirty and cannot be read, obtain replacements from your Komatsu forklift
distributor/dealer and attach the safety labels in the specified positions.
See "SAFETY LABEL STICKING POSITIONS (PAGE 2-31)".
MAKE SAFETY PLANS BEFOREHAND

Before operation, establish an operating plan and hold a meeting to discuss operating safety.
In confined areas, position a signalperson and carry out operations in accordance with his/her instructions.
FOLLOW THE SAFETY RULES IN PLACE

Do not operate the lift truck if you are fatigued, or when you have been drinking or have taken any medication
which can make you sleepy.
When carrying out operation, inspection, or maintenance of the lift truck, always follow all work shop rules, safety
regulations, and precautions.
During operation, always pay attention to safety and be careful of pedestrians and other surrounding conditions.
ENSURE SAFETY AT THE WORKING AREA

Always work on level surfaces and wipe up all oil or grease from the ground.
When working on quays, platforms, or docks, or other places where there is danger of falling, set up blocks to
prevent the lift truck from going over the edge.
Put warning signs up in dangerous places to warn the operator not to approach.
Mark the travel areas clearly and maintain the road surface in good condition.
Put up signs to prevent unauthorized lift trucks from entering areas where lift trucks are being operated.
Ensure that there is adequate lighting to enable safe operations to be carried out safely.
WEAR SAFETY CLOTHES WHILE IN OPERATION

Avoid loose clothing, jewelry, and loose long hair.
They can catch on controls or in moving parts and cause serious injury or death.
Always wear a hard hat and safety boots.
Depending on the working conditions, wear other safety
equipment in addition to the hard hat and safety boots.
2-2
.
SAFETY SAFETY MANAGEMENT
KEEP THE OPERATOR'S COMPARTMENT CLEAN AND TIDY

Keep the operator's compartment clean and tidy. Be sure to clean up all oil or mud. If the operator's hand or foot
slips, this may lead to a serious accident.
Do not leave tools or spare parts lying around in the operator's compartment. They may damage or obstruct the
control levers or pedals. Always keep them in the tool box when not being used.
Do not drive the lift truck if your hands are wet or covered with oil. Your hands will slip on the work equipment
control levers or directional lever, and this may cause a serious accident.
REDUCE LOAD FOR LIFT TRUCKS WITH ATTACHMENT

The permissible load for lift trucks equipped with any attachment is lower than the permissible load for the
standard lift truck, the reasons being;
1) The overall permissible load is lowered by as much as the weight of an attachment itself.
2) The load center shifts toward the front due to the thickness of an attachment itself.
Follow the load limit as indicated in the load capacity chart on the nameplate.
In some detachable type attachments and inserting type attachments, there is an additional load capacity chart
or attachment weight label provided at a certain place. In that case, follow the instructions in the chart or the label
when installing such an attachment.
UNAUTHRIZED MODIFICATION
Do not install any additional equipment, parts or the like on the lift truck, or modify the lift truck without prior written
consent from Komatsu Forklift. An additional counterweight or unauthorized modification of the lift truck can bring
about a negative effect on the stability or strength of the lift truck, and can also cause the danger of impairing its
safety.
Do not install any equipment or parts which obstruct or limit the operator's view.
DON'T REMOVE THE OVERHEAD GUARD AND BACKREST

The overhead guard is installed to protect the operator from falling objects. It is designed to withstand the force of
light boxes or small packages. It is not designed to withstand every possible impact.
Always be careful to prevent damage or injury from falling objects.
Do not use a Komatsu lift truck, when it is equipped with a non-genuine overhead guard or backrest*.
(*: Komatsu lift trucks are usually equipped with the optimum overhead guard and backrest when they are
shipped out of Komatsu Forklift plants.)
ENGINE EXHAUST GAS IS POISONOUS

Do not leave the engine running where there is poor ventilation.
The engine exhaust gas contains carbon monoxide. There is
danger that this will cause gas poisoning which may result in
serious injury or death.
2-3
.
SAFETY MANAGEMENT SAFETY
FIRE IS STRICTLY PROHIBITED IN REFUELING

Fuel is extremely flammable and can cause fires and explosions.
Carry out refueling away from flames or sparks.
Stop the engine when refueling.
After refueling,tighten the gas cap securely and wipe up any
spilled fuel.
REMEMBER THE FOLLOWING JUST IN CASE

When you feel something unusual with the lift truck, stop the work on the spot, move the lift truck to a safe place
for parking and stop the engine for safety. Then report to the supervisor.
Be sure that fire extinguishers have been provided and that you read the labels to ensure that you know how to
use them.
Know what to do in the event of a fire.
Be sure that you know the phone numbers of persons you
should contact in case of an emergency.
Provide a first aid kit at the storage point.
Should fuel be found leaking, do not operate the lift truck. Be
sure to make repair, stopping the leak before starting the
operation again, while reporting the trouble to the supervisor.
2-4
.
SAFETY SAFE TRAVEL
SAFE TRAVEL
JUMPING ON AND OFF FROM THE LIFT TRUCK IS STRICTLY PROHIBITED
When getting in or out of the lift truck, be sure to stop the truck
once and use the handrails (assist grip) as well as the step to
hold yourself securely.
Do not hold on the control levers or steering wheel when getting
on or off the lift truck.
Keep the handrails (assist grip) clean all the time, and repair
damage, if any.
DON'T TRY TO OPERATE THE LIFT TRUCK FROM OUTSIDE

Always keep your body under the overhead guard.
Do not stick the hand or foot out of the overhead guard.
DON'T ALLOW A PASSENGER

Never allow any other person to ride with you on the lift truck for
whatever reasons.
Do not use anyone for a makeshift human counterweight.
2-5
.
SAFE TRAVEL SAFETY
BE SURE TO WEAR THE SAFETY SEAT BELT

Always fit your seat belt correctly when operating. If your seat
belt is fitted incorrectly, there is danger of serious personal injury
if the lift truck should tip over.
Always check the seat belt mounts and check for any damage
to the seat belt. If any abnormality is found, repair or replace the
seat belt immediately.
CHECK THE SURROUNDINGS FOR SAFETY BEFORE STARTING UP THE ENGINE

Before stating the engine, check that the parking brakes are set,
and that the directional and speed levers are in the neutral
position.
Adjust the operator's seat and the steering wheel before starting
the engine. Always lock them in position after adjusting.
Adjusting the seat or steering wheel during operation is
dangerous as it may cause you to lose your balance or operate
the lift truck wrongly.
When starting the engine, first check that the surrounding area
is safe, and sit in the operator's seat.
Sound the horn before starting the engine to warn people
around.
Do not attempt to start the engine by intentionally short-circuiting
the engine starting circuit.
Do not attempt to jump-start the lift truck.
CHECK AND ADJUST THE REARVIEW MIRROR AND LAMPS

When reversing, never depend on the rearview mirror; the operator must visually check behind him. Also, adjust
the rearview mirror so that the operator can check from the operator's seat that the area behind the lift truck is
safe. Always keep the surface of the mirror clean. If the mirror is broken, replace it with a new one.
Check that the lamps light up correctly. Replace any broken bulbs (for lift trucks equipped with lamps).
2-6
.
SAFETY SAFE TRAVEL
MAKE A SAFETY CHECK BEFORE STARTING THE LIFT TRUCK

Before starting the lift truck, check that the surrounding area is
safe.
Before starting the lift truck, raise the forks [approx. 15 - 20 cm
(6 - 8 in) from the ground surface], and tilt the mast back.
When ready to start, release the parking brake.
A SUDDEN SHIFT OF THE F-R LEVER IS DANGEROUS

To change the travel direction, stop the lift truck once and then operate the F-R lever.
When operating the F-R lever or High/low speed lever, be sure to shift the lever only after fully depressing the
clutch pedal (clutch type lift trucks).
If the lever is shifted without the clutch being first disengaged, the lift truck will suddenly leap forward or in reverse
and can cause injury.
BE ALWAYS CONSCIOUS OF SAFETY WHILE DRIVING

Keep a clear view of the path of travel and observe for other traffic, personnel, and safe clearances.
When passing oncoming vehicles, reduce speed and keep a safe distance from the other vehicle.
In places where there are speed limits, observe the speed limit and maintain a safe distance from other vehicles.
When traveling, always pay careful attention to the area around
your lift truck, particularly in the direction of travel or when
turning.
Do not attempt to pass another lift truck or vehicle on a narrow
path or on a spot of limited view like a crossing.
When passing through a spot of limited view like a crossing, or
when running into a narrow path, sound the horn and check the
surroundings for safety.
Even if you sound the horn, not everyone in the surrounding
area will necessarily hear it. Always pay careful attention to the
movements of people in the surrounding area.
When crossing a passage or turning at a corner, stop the lift
truck once to confirm the safety around.
Always pay careful attention to the movements of people in the surrounding area, and take steps to prevent
people from entering the working area.
When traveling on a slope or through a crowded spot, always give way to a loaded lift truck.
2-7
.
SAFE TRAVEL SAFETY
DO NOT DRIVE IN ON THE ROUGH GROUND

Avoid traveling in places which are flooded or where there are
holes.
Do not try to drive the lift truck on soft ground.
Avoid curbs, rails, ditches, or other obstacles, and do not travel
directly over them.
Do not travel on slippery road surfaces.
When entering buildings, check the weight limit of the floor and
be careful not to exceed the limit.
DRIVING ON A ROAD SHOULDER IS STRICTLY PROHIBITED

There is danger that soft road shoulders may collapse, so do not
go near them.
Always maintain a safe distance from the edge of road
shoulders and platforms.
2-8
.
SAFETY SAFE TRAVEL
WHEN DRIVING INTO A RAILWAY WAGON, LORRY OR CONTAINER, EXERCISE EXTRA CARE
Do not travel on the edge of docks. There is danger that the lift
truck may fall, which may result in serious injury or death.
Before starting operations, check the load limit for the
gangplanks, and do not use them if they do not have ample
strength to take the weight of the lift truck when loaded.
Apply the brakes on the truck and block the wheels.
With trailers, use jacks and take steps to prevent the trailer from
sinking when the forklift truck travels on it.
When driving the forklift inside trucks, reduce speed when
backing out and be sure to check that the gangplanks are safe.
Be careful of pedestrians.
Tell the truck driver not to move the truck until the operation is
completed.
If there is some system to secure the truck to the dock, always
use this system. Secure the gangplanks so that they do not slip
and fall.
BE MINDFUL OF THE LIFT TRUCK'S MAX. HEIGHT AND WIDTH

Ensure that there is ample height and width for the lift truck to
pass.
Do not extend your hands or legs outside the operator's
compartment or the area covered by the overhead guard (safe
area).
Check that the surrounding area is safe.
Be careful of electric wires and other obstacles inside and
outside the building.
2-9
.
SAFE TRAVEL SAFETY
WHEN DRIVING UP OR DOWN A SLOPE, EXERCISE EXTRA CARE

Do not turn, or travel across or at an angle on slopes. There is
danger that the lift truck will tip.
Before starting to drive up a slope, stop the lift truck and adjust
the clearance between the ground surface and the bottom of the
forks so that the bottom of the forks or pallet do not contact the
ground surface or the tip of the fork does not stick into the
ground when traveling.
For safe travel on slopes.

When loaded: Travel forward up the slope and in reverse down
the slope with the load upgrade.
When unloaded: Travel in reverse up the slope and forward
down the slope with the load-engaging means
downgrade.
On a downslope, drive down slowly and using the foot brakes.
When starting on slopes, the lift truck may start to move down
the slope depending on the amount the pedals are depressed.
Always leave ample room in front of and behind the lift truck
when starting on slopes.
WHEN MAKING A TURN, BE CAREFUL OF THE SWINGING TAIL

When turning while traveling forward, the counterweight will
swing far out. Keep an ample clearance from walls to ensure
safety.
When turning, travel slowly and be careful that the front or rear
wheels do not come off the ground.
When turning on soft road shoulders, there is danger that the
rear wheels may come off the road shoulder and cause the lift
truck to tip.
2 - 10
.
SAFETY SAFE TRAVEL
THE KIND OF OPERATION LIKELY TO OVERTURN THE LIFT TRUCK IS STRICTLY PROHIBITED
If the load-engaging means or load is raised, the center of
gravity of the lift truck will also rise and increase the danger of
the lift truck tipping. Do not turn the lift truck when the forks are
raised high.
Do not suddenly raise the forks or tilt the mast to the front or rear
when the forks are loaded. There is danger that the lift truck will
tip.
Reduce speed before turning the lift truck.
In particular, when traveling unloaded, the rear of the lift truck is
heavy. If the lift truck is turned at high speed, there is a greater
chance of tipping than when traveling with the forks loaded.
WHEN BACKING UP THE LIFT TRUCK, CHECK IN THE REVERSE DIRECTION VISUALLY
Before driving in reverse, make sure that there is no one behind
the truck before starting to travel.
The rear view mirror is simply an aid for checking the rear. When
driving in reverse, do not use the rear view mirror. Turn to face
the rear and check the area directly behind the lift truck. Even if
you sound the backup buzzer, the people behind th
Even if you sound the backup buzzer, the people behind the
truck do not necessarily hear it. Always check that there is no
one behind the truck before driving the truck. (For lift trucks
equipped with backup buzzer)
WHEN CARRYING A HIGH LOAD, USE A SIGNAL PERSON OR DRIVE BACKWARD

If the view to the front is obstructed by the load, turn to the rear
and drive the lift truck in reverse.
When driving in reverse with a high load, use a signalperson to
ensure the safety of the load and the safety in the surrounding
area.
2 - 11
.
SAFE TRAVEL SAFETY
PAY SPECIAL ATTENTION TO THE REARVIEW WITH A LPG CYLINDER-INSTALLED (GASOLINE ENGINE) LIFT
TRUCK
The installed LP gas cylinder partially blocks the rear view and poses a danger of hitting people around or piled
commodities, or run against a nearby building. Therefore, install backup warning devices (backup alarm buzzer,
rotating warning lamp, etc.) or backup safety checking devices such as a rearview mirror in order to warn people
around and check safety in the rear direction.
When installing optional warning devices, call your Komatsu Forklift distributor for details of installation.
APPLY THE BRAKES CORRECTLY WHILE RUNNING

Do not stop the engine while running.
When the engine is not running, the operating efforts for power steering and power brakes (if present) increase.
Thus it is dangerous to stop the engine while running.
If the inching pedal is depressed, the braking effect of the engine will be lost.
Do not use the brakes unnecessarily frequently. If your lift truck is a TORQFLOW transmission type and you hold
your foot rested on the inching pedal while operating it, the multiple clutch plates of the transmission will overheat,
deforming the clutch plates and disabling them from functioning properly in the worst case.
THE REQUIRED BRAKING DISTANCE DIFFERS DEPENDING ON THE ROAD CONDITIONS

When traveling downhill, it requires a longer distance for the lift truck to stop than when traveling on level ground.
When traveling downhill, reduce the speed and make sure that you have ample room at the bottom of the slope
to stop.
When traveling on wet surfaces, it requires a longer distance to stop than when traveling on normal road surfaces.
Always leave ample room to stop.
2 - 12
.
SAFETY SAFE TRAVEL
FOLLOW THE STEPS FOR PARKING

CHECK ITEMS WHEN PARKING
1. Stop the lift truck on level ground.
2. Apply the parking brake securely to make sure that the lift truck
cannot move.
3. Set the directional lever and speed lever to neutral.
4. Tilt the mast forward and lower the fork to the floor.
5. Turn the starting switch to the OFF position.
6. Pull out the starting switch key and leave the lift truck.
PARK THE LIFT TRUCK IN A SAFE PLACE

Park the lift truck in the specified place.
Park the lift truck on a firm surface.
Do not park near any emergency exit, stairway, fire extinguisher, or other safety equipment. Park the lift truck in
a place where it will not obstruct pedestrians or other vehicles.
Never park the lift truck near any flammable object.
If there is no way to avoid parking on a slope, immobilize the lift truck by putting blocks under the tires in addition
to normal parking procedures.
DON'T USE A LIFT TRUCK WITH A DEFECT

Remove the key from the faulty lift truck and hang signs in the
operator's compartment to prevent its use.
If the lift truck has suffered a failure and the lift truck must be
parked without lowering the forks, put markers on the tips of the
forks and take steps to prevent pedestrians or other vehicles
from hitting the forks.
Select a parking place where people or vehicles do not pass,
and stop the lift truck so that it is difficult for anyone to go under
the forks. (The area under the forks is a danger zone.)
SHOULD THE LIFT TRUCK BECOME INOPERATIVE IN A DANGEROUS PLACE LIKE A RAILROAD CROSSING, LET
ALL PEOPLE AROUND KNOW THE FACT IMMEDIATELY
If engine trouble occurs on a railroad crossing and the lift truck does not move, it is impossible to use the starting
motor as can be done on an automobile.
(This is because a neutral safety switch is installed.)
In such an emergency, light a flare or smoke candle to warn approaching trains and people in the area that there
is a broken-down truck on the tracks.
2 - 13
.
SAFE TRAVEL SAFETY
DON'T USE A LIFT TRUCK TO TOW ANOTHER BROKEN-DOWN LIFT TRUCK

If there is any problem with the brakes or steering system of your lift truck, do not use another lift truck to tow it.
There is danger that the lift truck may run away.
DON'T USE THE DRAWBAR PIN FOR ANY OTHER PURPOSE THAN WAS ORIGINALLY INTENDED FOR
Do not use the drawbar pin for any other towing purpose than to
bail out a stuck lift truck, or to be towed by another lift truck or to
be hoisted.
The towing pin at the back of the counterweight is provided to
pull out the lift truck when it has got stuck up in dirt or a ditch as
well as when it is load on a truck.
2 - 14
.
SAFETY LOADING OPERATIONS
LOADING OPERATIONS
TAKE GOOD CARE IN LOADING AND UNLOADING OPERATION
Always operate the mast and forks from the operator's compartment.
Be careful not to operate the lever by mistake. There is danger that the forks or work equipment may cause
serious injury.
KEEP UNAUTHORIZED PEOPLE OFF THE WORKING AREA AND CHECK A SIGNAL PERSON IS ON DUTY
Do not allow anyone except the signalperson in the working area.

Do not let any person or other lift truck come close during operation.
When working with a signalperson, always follow their instructions.
DON'T GO UNDER THE LIFTED FORK

The space under a lifted fork is an area of danger, so never allow
anyone to go under the fork. There is a danger of personal injury
that a person can be crushed under the fork when it comes down.
WORKING ON THE FORK IS STRICTLY PROHIBITED

Do not let anyone place a load on the forks.
Do not let anyone directly remove the load from the forks.
Standing on the forks is dangerous because the forks are
slippery and the load may move.
Do not use anyone to keep the load stable.
The lift truck may move unexpectedly, causing the load to fall
and crush the person.
2 - 15
.
LOADING OPERATIONS SAFETY
BE CAREFUL NOT TO GET CAUGHT IN THE MAST STRUCTURE

Never put your hands or feet into the mast structure. There is
danger that you will get caught in moving parts and be seriously
injured.
DON'T CLIMB ON THE MAST OR BACKREST

If you climb on the mast or backrest, there is a danger that you
get caught up in the moving parts or fall off.
USE A PALLET OR SKID OF SUFFICIENT STRENGTH

Always be sure that the pallets and skids have ample strength. If broken or damaged pallets or skids are used,
there is a risk that the load may fall.
Always check that the load is positioned securely and safely on the pallet before driving the truck.
HANDLE A LONG OR WIDE LOAD WITH EXTRA CARE

Be extremely careful when carrying long or wide loads. Raise
the load slowly and be careful not to touch anything in the
surrounding area.
Keep the load as low as possible and be sure to maintain the
balance.
When turning, operate slowly and be careful not to let the load
move.
2 - 16
.
WATCH OUT OVERHEAD

As the fork goes up, the mast height increases. Be mindful of
this fact during the operation.
Take care so that the mast or the overhead guard will not hit
electric wirings, piping, sprinklers, beams in the ceiling, etc. If
such hitting occurs, there is the danger that the load on the fork
drops off or the lift truck tips over.
OVERLOADING IS STRICTLY PROHIBITED

Do not load the lift truck over the max. capacity shown in the load
capacity chart, otherwise there is the danger that the rear
wheels come off the ground; the operator loses control of the lift
truck; and the truck tips over. Moreover the stack on the fork can
collapse.
Never exceed the max. load shown in the load capacity chart on
the nameplate. (See "LOAD CENTER AND ACTUAL
CAPACITY (PAGE 2-29)")
DON'T HANDLE A LOAD IN AN INSECURE MANNER

Make sure that the center of gravity of the load is in line with the
center of the lift truck. Do not carry loads off-center. There is
danger that unbalanced loads may cause the lift truck to tip.
Place the load so that it contacts the load backrest.
Do not handle unstable loads. If there is danger that the load
may fall off, secure it in position and take steps to prevent the
load from collapsing or falling.
2 - 17
.
LOADING OPERATIONS SAFETY
DON'T HANDLE A LOAD EXCEEDING THE BACKREST HEIGHT

Keep the height of the load within the height of the load backrest.
Do not carry any load that is higher than the load backrest. If the
load is higher than the load backrest, there is danger that it will fall
back on top of the operator. This may lead to serious injury or
death.
BE CAREFUL OF THE FORK TIP

Do not allow the tips of the forks to get close to people. The tips
of the forks are pointed, so there is a risk that they may cause
injury.
Do not attempt to hook something with the tips of the fork,
otherwise the hooked object can suddenly come off the tip, and
the reaction causes big danger to the lift truck as well as to the
hooked object.
DON'T USE THE FORK TO PUSH OR PULL A LOAD

There is a risk that the load will be damaged or fall.
2 - 18
.
DON'T TILT THE MAST FORWARD WITH A LOAD ON THE FORK.

Do not tilt the mast forward with the load raised. Do not raise the
load when the mast is tilted forward. There is danger of the load
falling or the truck tipping over.
Do not travel with the mast tilted forward.
Do not load and unload on slopes.
BE CAREFUL OF CHAIN SLACKENING

If there is any slack in the chain, the mast rail or forks may catch in
the load or a shelf, and there is danger that the load may fall and
the lift truck tip.
Always be careful that there is no slack in the chain when pulling
the forks out from pallet or shelf.
DON'T USE THE LIFT TRUCK THE WRONG WAY

Do not use the lift truck for any other purpose than was originally
intended for (the loading work using the fork or attachments).
Do not use the forks to open or close the doors of railroad cars
or warehouses.
Do not push any other vehicle.
Do not hook ropes on the forks and use the forks to lift loads.
Do not use the drawbar pin for towing operations.
2 - 19
.
SAFETY IN PERIODIC MAINTENANCE SAFETY
SAFETY IN PERIODIC MAINTENANCE

THE PERIODIC MAINTENANCE WORK TO BE CARRIED OUT ONLY BY QUALIFIED PERSONNEL
Only persons authorized by the owner or operator of the equipment and having proper certification (local or
national) may carry out inspection, maintenance and repairs of the lift truck.
If inspection, maintenance, or repair work is carried out incorrectly, it is very dangerous.
PLACE OF PERIODIC MAINTENANCE WORK

When carrying out inspection and maintenance, use a level, dry, dust-free area.
If the work is carried out inside a building, make sure that there is ample ventilation.
PRECAUTIONS BEFORE PERIODIC MAINTENANCE WORK

Read rules and regulations for safety control, safety driving, and loading and unloading operation carefully and
understand them fully.
To be prepared in the event of a fire, have a fire extinguisher nearby and make sure that you know how to use
it.
Before carrying out inspection, lower the forks to the ground and stop the machine.
Before starting the inspection and maintenance work, turn the engine starting switch to the OFF position and keep
the engine at a standstill.
Keep the engine starting switch in the OFF position except when otherwise required in order to keep the engine
at a standstill.
Set the MAINTENANCE IN PROGRESS plate in a place in the operator's compartment or near the control panel
where it is easy to see.
Set the FORWARD/REVERSE lever, high/low speed lever, and work equipment lever to the neutral position.
Apply the parking breaks and put stoppers (chocks) both before and behind the tires.
PRECAUTIONS DURING PERIODIC MAINTENANCE WORK

Wipe off any oil or grease. Immediately wipe up any oil that has leaked.
If the lift truck is dirty, it becomes difficult or impossible to find cracks or other problems. Always clean the lift truck
before starting inspection.
Do not smoke or allow any flame to exist under any circumstances.
Do not use any cloth which is soaked in oil, or grease. There is danger that it may catch fire.
Wear adequate working clothes and protective equipment (hard hat, safety shoes, goggles and gloves).
When working on top of the lift truck, be careful not to fall.
Do not put your feet under the forks.
When opening or closing the floor plate or engine hood, be careful not to get your hands or body caught.
When carrying out inspection with the forks raised, insert a stand under the inner mast to prevent the forks and
mast from dropping.
Before starting the inspection and maintenance work, disconnect the cable from the battery negative (-) terminal.
When carrying out job with another worker, decide who is the leader and carry out the job in accordance with
instructions from that person.
After finishing repair work, have a trial run of the lift truck.
During the trial run, start/operate the lift truck carefully because it is possible that the trouble has not been fully
corrected or that defective parts have not been removed.
PERIODIC INSPECTION OF CRITICAL REPLACEMENT PARTS

Replace critical safety parts with a new one periodically even if no anomaly is found with them. They tend to
deteriorate as the time goes by, and can cause fire or failure in the work equipment system.
However, if these parts show any abnormality before the replacement interval has passed, they should be
repaired or replaced immediately.
2 - 20
.
SAFETY SAFETY IN PERIODIC MAINTENANCE
USE OF RIGHT TOOLS AND EQUIPMENT

Always use tools that are suited for inspection and maintenance.
It is extremely dangerous to use broken tools or tools designed for another purpose.
BE CAREFUL OF BOILING ENGINE COOLING WATER

Immediately after using the lift truck, the engine coolant is at
high temperature and high pressure. Do not remove the radiator
cap under these conditions.
Hot water may spurt out and cause burns.
When removing the radiator cap, turn it slowly to release the
internal pressure.
When checking the coolant level, stop the engine and wait for
the engine and radiator to cool down before checking.
BE CAREFUL OF HIGH PRESSURE AND HIGH TEMPERATURE HYDRAULIC OIL

Immediately after using the lift truck, the oil is at high
temperature. Do not drain the oil or replace the filter when the oil
is hot. Hot oil may spurt out and cause burns.
Wait for the truck temperature to go down before carrying out the
inspection and maintenance work.
Do not forget that the work equipment circuits are always under
pressure. Do not add oil, drain oil, or carry out maintenance or
inspection before completely releasing the internal pressure.
If oil is leaking under high pressure from small holes, it is
dangerous if the jet of high-pressure oil hits your skin or eyes.
Always wear safety glasses and thick gloves, and use a piece of
cardboard or a sheet of plywood to check for oil leakage.
If you are hit by a jet of high-pressure oil, consult a doctor
immediately.
BE CAREFUL OF THE ROTATING COOLING FAN AND BELT

It is extremely dangerous if part of your body or a tool in the hand
gets caught up in the rotating fan or fan belt. Never touch them
in rotation.
When inspecting rotating parts, do so only after the engine
comes to a stop.
When inspecting the areas around rotating parts, do not allow
anything to come close which may get caught.
2 - 21
.
AVOID THE DANGER OF GETTING CAUGHT UP OR FALLING OFF

Never put your hands or feet into the mast structure. There is
danger that you will get caught in moving parts and be seriously
injured.
Do not use the mast as a ladder.
If you slip, there is danger that you will fall.
INSPECTION AND INFLATION OF TIRES

If the tire inflation pressure is low, it will affect truck stability.
However, do not inflate the tires immediately. The inflation
pressure may have gone down because of damage to the rim.
If the rim is damaged or cracked and the tires are inflated, there
is danger that the rim will break when the tire is under high
pressure, and this may cause personal injury or death.
For safety, when checking tire pressure, place your body in front
of the tread face of the tire. Do not check from the side face of
the tire.
Suitable qualifications are needed for tire inflation work. Always
have the work carried out by properly qualified personnel.
The tire inflation pressure on a forklift truck is several times
higher than the pressure on an automobile.
When the tires are being inflated, there is danger that dirt or dust may be thrown up by the compressed air and
enter your eyes, so always wear safety glasses.
2 - 22
.
HANDLING OF TIRES
Disassembly and assembly of tires should be carried out by tire
dealer.
The tire inflation pressure is extremely high, so caution is needed
when handling tires.
When removing a tire, do so only after the internal air is
released. Loosen hub nut (1) to remove the tire from the chassis.
If rim nuts (2) are installed, never touch them because it is very
dangerous to do so.
After replacing the tires, have a trial run to make sure that there
is no loose hub nut. If the tightening torque is not sufficient,
further tighten the hub nut to the specified torque. For the right
tightening torque, refer to "SERVICE DATA (PAGE 4-32)".
JACKING-UP (FOR INSPECTION AND REPLACEMENT OF TIRES)

Do not go under the forklift truck when it is jacked up.
Check the following before jacking up the lift truck. (For details,
see "REPLACING TIRES (PAGE 4-29)")
1)Check that there is no one on the lift truck.
2)Check that there is no load on the forks.
When jacking up, stop when the tires come off the ground
surface. Put blocks under both sides of the frame to prevent the
lift truck from coming down.
Put a tire stopper behind the tires in contact with the floor so that
the lift truck will not move freely.
2 - 23
.
HANDLING OF BATTERIES
Battery electrolyte contains sulfuric acid, and can quickly burn the skin and eat holes in clothing. If you spill battery
electrolyte on yourself, immediately shed the clothes, flush the part with a large quantity of tap water and then
consult a doctor.
Should battery electrolyte get into your eyes, flush them immediately with fresh tap water for 10 to 15 minutes and
then consult a doctor at once.
Should you drink battery electrolyte by accident, either drink a
large quantity of water or milk mixed with beaten egg white or
salad oil, and then consult a doctor at once.
Be sure to wear goggles, safety gloves and rubber-soled shoes
at the time of battery maintenance.
Batteries generate hydrogen gas. Hydrogen gas is highly
EXPLOSIVE, and is easily ignited with a small spark or flame.
Do not smoke or create any spark near the battery.
When inspecting or handling the battery, do so only after turning
the engine starting switch key to the OFF position and stopping
the engine.
When disconnecting the battery cables, disconnect the cable of the negative (-) terminal first. Conversely, when
connecting them again, connect the cable of the positive (+) terminal first.
Avoid short-circuiting the battery terminals through accidental contact with tools or other metal objects across the
terminals.
Tighten the battery terminals securely. Loose terminals can generate sparks and lead to an explosion.
When connecting the disconnected battery cables again, be sure of the positive (+) and negative (-) terminals well
in order to avoid wrong connection.
Tighten the battery caps securely.
When cleaning the battery, leave the battery caps tightened.
Do not put a metallic tool or plate on the battery terminals by accident. There is the danger that such a metallic
object causes short-circuiting, leading to a fire.
PRECAUTIONS WHEN CHARGING BATTERIES

When the battery is charged, hydrogen gas is generated and the battery is heated by the chemical change. To
prevent the danger of gas explosion, always do as follows.
Before charging the battery, check that the battery electrolyte level stays within the specified range. If the
electrolyte is found insufficient, add distilled or purified water without fail.
Carry out the charging operation in a well-ventilated place.
Do not smoke or allow any flame.
Start to charge the battery when the battery electrolyte temperature is below 35C (95F). (If the electrolyte
temperature is above 50C (122F), wait until it goes below 35C (95F).)
When using a battery charger to charge the battery, take the battery caps off.
PRECAUTIONS WHEN USING BOOSTER CABLES

ALWAYS wear safety glasses or goggles when starting the lift truck with booster cables.
When starting using the battery of another lift truck,do not allow the two lift trucks to touch.
Stop the engine before connecting the cables.
Be extremely careful not to let the cables get caught in the fan or fan belt.
Do not make a mistake about the right connection of the booster cables. Never let the positive (+) and negative
(-) terminals contact each other.
2 - 24
.
JUMP- STARTING THE ENGINE IS PROHIBITED.

Do not push the lift truck to start the engine. There is danger that the lift truck may suddenly start and operate
unexpectedly.
HANDLING OF BRAKE OIL

It is dangerous if the brakes do not work because in this condition, the lift truck cannot be stopped. Always do the
following.
Check the level of the brake fluid periodically.
Always use the specified brake fluid.
Check that the breather of the brake fluid reserve tank is not clogged.
Be careful not to let dirt or dust get into the brake fluid reserve tank.
HANDLING OF ANTI-FREEZE
Antifreeze can be a flammable. Keep away from flame when handling.
Antifreeze is poisonous, so do not drink it. If you drink it by mistake, drink large amounts of water, vomit it out, and
get medical attention immediately. Follow safety precautions on container.
HANDLING OF WASTES FROM LIFT TRUCK

Obey appropriate laws and regulations when disposing of harmful
objects such as oil, filters, and batteries.
HOISTING LIFT TRUCK

Never lift the truck by the overhead guard.
If the truck has to be lifted frequently, it is necessary to install
special lifting equipment, so please contact your Komatsu
Forklift distributor.
Fit wire ropes to the specified lifting points.
When lifting the lift truck, check that the wire ropes have ample
strength and are not damaged.
Never go under the lifted truck.
If the specified lifting point is the counterweight, check that the
counterweight mounting bolts are tightened to the specified
torque before carrying out the lifting operation. Check also that
there is no damage to the lifting portion on the counterweight.
When using the hooks on the counterweight to hoist the lift truck,
check beforehand that the counterweight mounting bolts are
tightened to the specified torque and that there is no abnormality
on the hooks.
2 - 25
.
STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING!) SAFETY
STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT

TRUCK FROM TIPPING!)
To operate the lift truck safely, it is important to understand the structure and stability of the lift truck.
STRUCTURE OF LIFT TRUCK

Forklift trucks basically consist of a lifting mechanism (fork and
mast) and a main body (vehicle). The front wheels act as a fulcrum
and the center of gravity of the lift truck and that of the load are kept
in balance. The relationship between the positions of these two
centers of gravity plays a very important role for the safety of the lift
truck.
CENTER OF GRAVITY OF LOAD

The loads carried by forklift trucks come in various shapes from
boxes to planks and long objects. To judge the stability of the lift
truck, it is important to distinguish the position of the center of
gravity for loads of various shapes.
2 - 26
.
SAFETY STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING!)
CENTER OF GRAVITY AND STABILITY

The stability of the lift truck is determined by the position of a
combined center of gravity resulting from combining the centers of
gravity of the lift truck and the load. When the lift truck is carrying
no load, the center of gravity of the lift truck remains unchanged.
On the other hand, when it is carrying a load, the center of gravity
of the lift truck shifts to a combined center of gravity from the
centers of gravity of both the lift truck and the load. The position of
the center of gravity of a load changes as the mast is tilted back or
forth, or it is raised or lowered. The position of the combined center
of gravity also changes depending on the following factors.
Size, weight, shape of load
Lifting height
Tilting angle of mast
Inflation pressure of tires
Acceleration, deceleration, turning radius
Condition of road surface, angle of road
Type of attachments
STABLE RANGE OF CENTER OF GRAVITY

For the lift truck to remain stable, the combined center of gravity of
the lift truck must come within a triangle formed by three points of
the left and right front wheels in contact with the floor and the center
of the rear axle, i.e. the center of gravity stable range.
When the position of the combined center of gravity shifts beyond
the front axle, the lift truck will tilt forth with the front wheels acting
as a fulcrum. On the other hand, when the position of the combined
gravity of center shifts out of the center of gravity stable range, the
lift truck will tip over in the shifting direction.
2 - 27
.
ACTUAL CAPACITY
The horizontal distance from the position of the center of gravity of
a load on the fork to the upright backrest of the fork iscalled a load
center.
Actual capacity means the maximum weight of a load that can be
loaded at a certain load center.
A load capacity chart is given in the name plate. The chart shows
the relationship between the actual capacity and a load center.
As a load center shifts toward the fork tips, so does the positionof
the combined center of gravity, too. Therefore, the load hasto be
decreased accordingly in the actual operation.
When the lift truck is equipped with an attachment, or when the
mast is raised high, the actual capacity is reduced. Take this fact
into consideration in such a case.
LOAD CAPACITY CHART

In the load capacity chart, capacity (2) is shown in relation to load
center (1).
Capacity values are determined according to each model on the
condition of the specifications shown in area (3).
Before proceeding to loading a load, make sure that the load center
and the load are well within the confines of capacity.
When the load is in a complex shape, pull the load closer to the
backrest so that the heaviest portion of the load comes to the fork
center.
Should a load be loaded beyond the confines of capacity, it would
pose a big danger to the lifting truck as the rear wheels (for
steering) are likely to lift off the ground, letting the operator lose
control of steering.
To make the things still worse, the lift truck will likely tip over while
in operation. Therefore, always make sure that the load is
absolutely within the confines of capacity.
When the lift truck is equipped with any attachment, the following marks are shown in the label.
Mark
Kind of Attachment
Kind Mark Capacity Mark
Side Shift F S * * * *
Fork Positioner F M * * * *
Load Stabilizer F T * * * *
3-way Stacker F W * * * *
Hinged Fork H F * * * *
Push Pull P P * * * *
Pusher P A * * * *
Clamp C * * * * *
Rotary Clamp R S * * * *
Rotary Fork R F * * * *
Ram L * * * * *
Spreader N * * * * *
Hook K * * * * *
When a detachable attachment or insert type attachment is installed, the actual capacity changes accordingly. For
this reason, an additional load capacity chart is affixed on the engine hood on the right side of the operator's seat.
So be sure to obey the load indicated in the chart.
2 - 28
.
SAFETY STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING!)
LOAD CENTER AND ACTUAL CAPACITY

A nameplate shown at right is just an example. In the actual
operation, follow the instructions on a nameplate of the actual lift
truck.
An example here shows a nameplate for a lift truck which has a
mast of max. fork height of 3.0 m and which is not equipped with
any attachment.
When the load center is 500 mm ---- Capacity: 2,500 kg

When the load center is 600 mm ---- Capacity: 2,250 kg
When the load center is 1,000 mm --- Capacity: 1,620 kg
Even when the load center is shorten than 500 mm, the actual
capacity is 2,500 kg.
It is required to replace the present nameplate with a new one when the present nameplate is broken or has become
difficult to read. In that case, call your Komatsu Forklift distributor asking for a new replacement nameplate.
SPEED AND ACCELERATION

If a stationary object is not subjected to external force, it will remain stationary. In the same way, if a moving object
is not subjected to external force, it will continue to move at the same speed. This is called inertia.
Because of inertia, a force is applied towards the rear when the lift truck starts to move, and is applied towards the
front when the lift truck stops. If the brake are applied suddenly, there is danger of a large force being applied
towards the front which may make the lift truck tip or the load to be expelled.
When the lift truck is turned, a centrifugal force is applied to the outside from the center of the turn.
This force pushes the lift truck to the outside and makes it tip. The range of stability to the left and right is particularly
small, so it is necessary to reduce speed when turning, in order to prevent the lift truck from tipping. If the lift truck
is traveling with a raised load, the position of the overall center of gravity is high, so the danger of tipping to the front,
left, or right becomes greater.
2 - 29
.
HOW TO MOVE A DISABLED LIFT TRUCK

Use extra care when towing a lift truck if there is a problem with any the following;
a. Brakes do not operate correctly.
b. Steering does not operate correctly.
c. Tires are damaged.
d. Traction conditions are bad.
e. The lift truck must be moved on a steep grade.
If the steering pump motor does not operate, steering control of the lift truck can be slow.
This can make the control of the lift truck difficult. If there is no power, there is no power steering.
DO NOT tow the lift truck if there is no power. Poor traction can cause the disabled lift truck or towing vehicle to slide.
Steep grades will require additional brake force to stop the lift truck.
Never carry a disabled lift truck unless the lift truck MUST be moved and cannot be towed. The lift truck used to carry
the disabled lift truck MUST have a rated capacity equal to or greater than the weight of the disabled lift truck. The
capacity must be for a load center equal to half the width of the disabled lift truck. See the nameplate of the
approximate total weight. The forks must extend the full width of the disabled lift truck. Center the weight of the
disabled lift truck on the forks and be careful not to the damage the under side of the lift truck.
How To Tow The Lift Truck

1.The towed lift truck must have an operator.
2.Tow the lift truck slowly.
3.Raise the carriage and mast channels from moving.
4.If another lift truck is used tow the disabled lift truck, that lift truck must have an equal or larger capacity than the
disabled lift truck. Install an approximate half-capacity load on the forks of the lift truck that is being used to tow
the disabled lift truck. This half-capacity load will increase the traction of the lift truck. Keep the load as low as
possible.
5.Use a towing link made of steel that attaches to the tow pins in the counterweights of both lift trucks.
2 - 30
.
SAFETY SAFETY LABEL STICKING POSITIONS
SAFETY LABEL STICKING POSITIONS

Keep these labels clean. If a label comes off, stick it on again or replace with a new one.
Concerning labels other than the safety labels, use these in the same way.
SAFETY LABEL STICKING POSITIONS
2 - 31
.
SAFETY LABEL STICKING POSITIONS SAFETY
(1) Prohibit the operator from riding on the forks and (2) Caution to avoid getting hand caught.
lifting/lowering himself.
Never enter the area under the forks.
2 - 32
.
(3) Caution before carrying out inspection and (4) Caution to avoid getting hand caught
maintenance work as well as operation
(5) Radiator cap
(6) Battery cautions

Gasoline engine lift truck
2 - 33
.
SAFETY LABEL STICKING POSITIONS SAFETY
Diesel engine lift truck
(7) Seating capacity --- 1 person only
2 - 34
.
(8) Avoiding danger if lift truck overturns during operations

If the steering is operated suddenly during operations, there is danger that the lift truck may lose its balance and tip
over. To avoid danger, always observe the following precautions strictly.
(a) Always wear your seat belt during operations.

(b) Make sure that you read and understand the Operation and Maintenance Manual before operating the lift truck.
(c) Never jump off the lift truck.
(d) Lean in the opposite direction from the direction in which the lift truck is tipping.
(e) Grip the steering wheel tightly.
(f) Brace yourself with both feet to support your body.
Items (c) to (f) are for when the lift truck tips over.
For safety label (1), order Part No. 3EB-96-25131

For safety label (4), order Part No. 37C-1KB-3100
For radiator cap (5), order Part No. 3EB-04-21130
For safety label (6), order Part No.
2 - 35
.
INTRODUCTION OF OPTIONAL EQUIPMENT SAFETY
INTRODUCTION OF OPTIONAL EQUIPMENT

Various safety devices are available as options. If the operating conditions demand, please install these devices.
The devices listed below are only examples. Various other devices are also available.
For details, please contact your Komatsu Forklift distributor.
REAR LAMP
Install this when carrying out operations at night which require the rear area to be lighted.
(The law demands that sufficient lighting be provided to ensure safety.)
HIGH BACKREST
This improves the support for high loads and improves the stability of the load.
WIDE FORK CARRIAGE

This improves the support for wide load and improves the stability.
SPEEDOMETER
This shows the travel speed (km/h) and distance traveled by the lift truck.
SPEED ALARM
When the lift truck exceeds the preset speed, a buzzer sounds to warn the operator.
SAFETY CHECKER
The following warning lamps may be added to the instrument panel.
Battery electrolyte level warning lamp
Air cleaner element clogging warning lamp
Radiator cooling water level warning lamp
2 - 36
.
SAFETY TOWING
TOWING
HOW TO MOVE A DISABLED LIFT TRUCK

Use extra care when towing a lift truck if there is a problem with any the following;
a. Brakes do not operate correctly.
b. Steering does not operate correctly.
c. Tires are damaged.
d. Traction conditions are bad.
e. The lift truck must be moved on a steep grade.
If the steering pump motor does not operate, steering control of the lift truck can be slow.
This can make the control of the lift truck difficult. If there is no power, there is no power steering.
DO NOT tow the lift truck if there is no power. Poor traction can cause the disabled lift truck or towing vehicle to slide.
Steep grades will require additional brake force to stop the lift truck.
Never carry a disabled lift truck unless the lift truck MUST be moved and cannot be towed. The lift truck used to carry
the disabled lift truck MUST have a rated capacity equal to or greater than the weight of the disabled lift truck. The
capacity must be for a load center equal to half the width of the disabled lift truck. See the nameplate of the
approximate total weight. The forks must extend the full width of the disabled lift truck. Center the weight of the
disabled lift truck on the forks and be careful not to the damage the under side of the lift truck.
the tow pins in the counterweights of both lift trucks.
TOWING
How To Tow The Lift Truck
1.The towed lift truck must have an operator.
2.Tow the lift truck slowly.
3.Raise the carriage and mast channels from moving.
4.If another lift truck is used tow the disabled lift truck, that lift truck must have an equal or larger capacity than the
disabled lift truck. Install an approximate half-capacity load on the forks of the lift truck that is being used to tow
the disabled lift truck. This half-capacity load will increase the traction of the lift truck. Keep the load as low as
possible.
5.Use a towing link made of steel that attaches to the tow pins in the counterweights of both lift trucks.
2 - 37
.
.
OPERATION
3-1
.
GENERAL VIEW OPERATION
GENERAL VIEW
GENERAL VIEW OF LIFT TRUCK
(1) Mast (10) Head lamp

(2) Lift chain (11) Operator's seat
(3) Lift cylinder (12) Engine hood
(4) Backrest (13) Counterweight
(5) Tilt cylinder (14) Rear wheel
(6) Fork carriage (15) Front wheel
(7) Fork (16) Assist grip
(8) Head guard (17) Fuel filter
(9) Turn signal lamp
3-2
.
OPERATION GENERAL VIEW
INSTRUMENTS AND CONTROLS

METER PANEL
(1) Fuel gauge (8) Sedimenter warning lamp (diesel engine lift truck)
(2) Neutral indicator lamp Meintenance lamp (gasoline engine lift truck)
(3) Engine oil pressure warning lamp (option)
(4) Charge warning lamp (9) Glow indicator (diesel engine lift truck)
(5) Operation indicator (displays during operation) (10) Engine water temperature gauge
(6) Hour meter (11) Option meter (option)
(7) Lifting interlock display lamp (option)
3-3
.
GENERAL VIEW OPERATION
OPERATOR'S COMPARTMENT
(12) Starting switch (18) Parking brake lever

(13) Horn button (19) Accelerator pedal
Press button in the middle of the steering wheel to (20) Brake pedal
sound the horn. (21) Clutch pedal (clutch type lift truck)
(14) FORWARD/REVERSE lever Inching pedal (TORQFLOW transmission lift
(TORQFLOW transmission lift truck) truck)
(15) FORWARD/REVERSE lever This pedal is used for fine control when driving the
(clutch type lift truck, A or C type) lift truck slowly forward or in reverse for loading or
High/low speed lever unloading.
(clutch type lift truck, B type) (22) Lift lever
(16) High/low speed lever (23) Tilt lever
(clutch type lift truck, A or C type) (24) Tiltable steering wheel lock lever
FORWARD/REVERSE lever (25) Brake oil reservoir tank
(clutch type lift truck, B type)
(17) Combination switch
(turn signal lamp and lamp switch)
3-4
.
OPERATION EXPLANATION OF COMPONENTS
EXPLANATION OF COMPONENTS
The following is an explanation of the devices employed to operate the lift truck.
To carry out suitable operations correctly and safely, it is important to understand fully the method of operating the
equipment and the meanings of the displays.
METER PANEL
NOTICE
How to check a blown bulb of each warning lamp
(1) Check that each warning lamp lights up when the engine starting switch key is turned to the ON position.
(2) If there is any warning lamp that does not light up, check if the bulb is blown.
Do not climb on top of the dashboard. There is the danger that your foot may slip and you fall off.
FUEL GAUGE
Fuel gauge (1) indicates the level of the remaining fuel with a
needle.
Check the remaining fuel level with the engine starting switch key
in the ON position.
Position (A): it indicates that there is little fuel left.
Position (B): it indicates that the fuel tank is full now.
Do not use up all the fuel. Fill the fuel tank before the fuel runs out.
NEUTRAL INDICATOR LAMP

Neutral indicator lamp (2) lights up when the forward / reverse lever
is in the neutral position.
Before starting up the engine, be sure to turn the engine starting
switch key to the ON position and check that this lamp is on.
TRAVELING INTERLOCK DISPLAY LAMP (TORQFLOW TRANSMISSION LIFT TRUCK)

Travel Lock Lamp (Torque converter type only)
Travel lock lamp (2) is the same as the neutral position display
lamp. If the operator leaves the lift truck with the forward-reverse
lever in the F or R position, the lamp begins to flash and warns that
the lift truck cannot be run. When the operator is seated correctly
and returns the lever to the neutral position, the lamp stops flashing
and it can be run again.
3-5
.
EXPLANATION OF COMPONENTS OPERATION
ENGINE OIL PRESSURE WARNING LAMP

Engine oil pressure warning lamp (3) acts to indicate whether the
engine lubrication oil pressure is normal or not.
This lamp lights up when the engine starting switch key is turned to
the ON position and goes off after the engine startup. Then it is
functioning normally.
Should the lamp light up during the work, stop the work
immediately and check the engine lubrication system for any
abnormality.
CHARGE WARNING LAMP

Battery charging warning lamp (4) indicates how the alternator is
generating power.
Should the lamp light up during the work, check the electrical
system for any abnormality.
OPERATION INDICATOR
Operation indicator (5) acts to indicate that the hourmeter is
functioning.
While the engine starting switch key is in the ON position, a sand
glass mark on the left side of the hourmeter keeps flashing.
HOUR METER
Hourmeter (6) begins to work when the engine starting switch key
is turned to the ON position, and indicates the cumulative value of
operating hours. (While the hourmeter is in operation, the
operation indicator keeps flashing.)
The last digit advances by 1 (meaning 0.1 hour) when the engine
starting switch key is kept in the ON position for 6 minutes, or when
it is turned to the START position.
3-6
.
LIFTING INTERLOCK DISPLAY LAMP

Loading locking lamp (7) is a lamp to indicate that the seat switch
is on and thereby loading work is blocked.
The lamp is in a normal condition if it lights up when the seat switch
is turned ON and goes off after the engine startup.
If the operator does not sit in the seat in the correct posture, the
lamp flashes, indicating that the lift truck is blocked from engaging
in loading work. If he/she sits in the seat correctly, then the lamp
stops flashing, enabling the lift truck to start loading work.
SEDIMENTER WARNING LAMP (DIESEL ENGINE LIFT TRUCK)

Sediment warning lamp (8) is a lamp to indicate that there issome
water accumulated in the fuel filter.
Should the lamp light up during the work, drain water accumulated
in the fuel filter. If water is left inside the fuel filter, the functions of
the fuel injection pump and injection nozzles will likely be lowered.
For a water draining method, refer to "MAINTENANCE OF

ENGINE (PAGE 4-19)" (PAGE 4-20) of MAINTENANCE.
MAINTENANCE LAMP
NOTICE
If the lamp begins to flash, stop the work on the spot and report the trouble
to the administrator, or call your Komatsu Forklift distributor for checkup.
Maintenance lamp (8) begins to flash to inform the operator that

something abnormal has occurred in the control system.
In a diesel engine lift truck, the sediment warning lamp doubles as
a maintenance lamp.
The lamp is in a normal condition if it lights up when the engine
starting switch key is turned ON and goes off after the engine
startup.
3-7
.
GLOW INDICATOR (DIESEL ENGINE LIFT TRUCK)

Glow indicator (9) acts to indicate the condition of the enginebeing
preheated.
The lamp lights up when the engine starting switch key is turned to
the ON position and goes off when engine preheating is finished.
Lamp ON: the glow plug is heating the engine.

Lamp OFF: the glow plug has finished heating the engine.
REMARKS
The lamp goes off in approx. 8 seconds irrespective of the ambient
temperature.
ENGINE WATER TEMPERATURE GAUGE

NOTICE
If the indicator enters the red range, stop the work immediately and park
the truck in a safe place. Then take corrective actions against engine
overheating. (See "ACTIONS IN ENGINE OVERHEATING (PAGE 3-31)".)
Engine cooling water temperature gauge (10) indicates theengine

coolant temperature with a needle.
White range: the coolant temperature is normal.
Red range: the coolant is overheated.
DIGITAL LOAD METER (OPTION)

Digital load meter (10) measures a load on the fork in a simple way
and displays the value.
When this meter is installed, the engine water temperature gauge,

a standard part, is moved to the place of optional meters.
3-8
.
OPTION METER (OPTION)

When the following meters and gauges are installed in the lift truck
as an optional part, they are installed in the place indicated with an
arrow in the figure at right.
Speedometer
Ampere meter (ammeter)
TORQFLOW transmission oil temperature gauge
Engine cooling water temperature gauge (when the lift truck is
equipped with a digital type load meter)
A maximum of two optional meters and gauges can be installed.

1 meter: gauge to be installed: on the left side
2 meters: gauges to be installed: both on the left and on the right
side (Either the left side or right side is to be determined
by a combination of the selected optional meters and
gauges.)
3-9
.
REMOVING AND INSTALLATION OF ATTACHMENTS
SAFETY PRECAUTIONS
WARNING
The attachment(s) and major components are heavy and can cause serious injury if improperly handled.
1. Secure the truck against accidental movement of truck of attachments when work is being carried out. When
working underneath raised load-handling attachments, always secure them to prevent lowering.
2. When repairing or renewing hydraulic and electrical components all truck related setting values must be
observed. Under no circumstances may the working speeds be altered (e. g. lift speed, side shift speed).
3. Personnel may not remain in any Danger Zone in which they are at risk due to movement of the truck,
attachments or lift gear, or any Danger Zone into which descending or dislodged parts may fall.
4. Do not climb onto any part of the truck, which is in motion (e. g. mast, carriage, etc.).
5. No servicing should be carried out on the hydraulic system until the mast, carriage or relevant component has
been suitably supported or restrained.
6. Lower the carriage until the forks are resting on the ground and the lift chains are still taut.
FORKS
1. Release the fork stopper.
Move the forks toward center, fit the lower hook into the notch and remove the fork.
2. Replacement is the reverse of the removal procedure. Smear the fork hooks with grease and adjust the fork
width to suit.
3. Replacement is the reverse of the removal procedure. Smear the fork hooks with grease and adjust the fork
width to suit.
3 - 10
.
CARRIAGE
1. Disconnect the lift chains from the carriage and tie the ends of the chain to the outer mast upper cross member.
NOTICE
If a side shift carriage is fitted, disconnect the hydraulic hoses at the carriage, draining the fluid into a suitable container. Blank
the opened connections to prevent ingress of foreign matter.
2. Raise the mast inner section under power until the bottom of the inner section clears the carriage top roller
assemblies. Ensure that the lift chains do not foul during raising.
3. Reverse the truck away from the carriage.
4. Replacement of the carriage is the reverse of the removal procedure. If a side shift carriage is fitted, operate to
both extremes of travel several times to expel air from the system.
5. With the mast vertical, support the mast securely by attaching lifting tackle to the lifting eyes on the upper cross
brace indicated by the crane hook label. Remove tilt cylinder to mast pivot pins.
MAST
Prior to removal of the mast, detach the carriage and forks-refer to par 2 and 3. Remove the drive wheels (if
required).
1. Disconnect hydraulic pies from lift cylinders and blank off all open ends to prevent the ingress of foreign matter.
2. Inclining the mast forward a little from its vertical position, remove the dif mounting cap bolt.
CAUTION
Residual oil will be discharged during disconnection.
3. Reassemble is the reverse of the removal sequence, noting the following:

4. Before installing, inspect the truck carriage to make sure that the locating notches along the top of the truck
carriage are undamaged and that there are no obstructions on the faceplate itself.
1) Tighten to the correct torque, the mast locking bolts - refer to repair manual for torque figure.
2) If any removal of components affecting tilt angles have been carried out, check and adjust tilt angles. Refer
to the repair manual for further information.
3) Open both restrictor fittings completely by loosening the lock nut and backing out the threaded shaft. The
restrictor is wide open when 1/2 inch of the shaft is exposed above the tightened lock nut. Opening the
valves completely before making the adjustment is important, because the speed of clamp operation is
directly affected by the degree of restriction in the lines. The fittings should be as wide open as possible with
both arms operating at the same speed.
WARNING
Ensure that all locking devices are engaged upon assembly of attachment.
INSTALLATION/ASSEMBLY OF SIDE SHIFT, FORKSPREADER OR CLAMP ATTACHMENTS

The side shift, forkspreador and clamp attachments all have a common method of installation/assembly as follows:
1. Place the clamp into an upright position in preparation for mounting it on the truck.
2. Remove the lower mounting hooks from the back of the clamp frame.
3. Attach the two jumper hoses securely to the clamp's check valve before connecting them to the junction block
on the truck carriage.
3 - 11
.
4. The open line on the top of the valve is the "clamp open" circuit. The line on the side of the valve is "clamp close"
circuit.
5. If the hose junction block is located on the upper portion of the truck carriage, do not connect the jumper hoses
to it until the clamp is mounted on the truck. Lay the hoses over the top of the frame. However, if the junction
block is located on the lower portion or in the center opening of the carriage, and thus nearly inaccessible when
the clamp is mounted, attach the jumper hoses securely before installing the unit.
6. Install the clamp on the truck. It may be lifted onto the truck or simply positioned on the floor (and blocked up
under the frame and arms) or placed on a pallet so that the truck may be driven up and the truck carriage moved
under the upper mounting hooks on the frame. Line up the locating lug on the clamp with the center notch on
the truck carriage. (The carriage can be raised into the hooks at this point). Be careful not to pinch, twist, or
otherwise damage the jumper hoses in mounting. After the unit has been placed on the truck, bolt the lower
mounting hooks into position on the lower clamp frame, firmly securing it to the truck carriage.
7. Attach the hoses to the carriage junction block.
8. It is normal at this point to re-check the hoses from the truck valve to the clamp. Make sure that the hoses are
routed correctly, and that all connections are tight. For best results, there should be as few 90 degree bends and
other similar flow restrictions as possible in the hydraulic circuits. Check the mounting hooks to be certain that
the clamp is solidly mounted to the truck carriage.
9. Start the truck. Operate the clamping function several times to remove any airtrapped in the system. Before
proceeding to the next step, check to make sure that the retaining nuts on the anchor and rod ends of each
clamp cylinder are tight.
10. Adjust the rate of arm travel. When the clamp is correctly adjusted both arms should close together from full
extension at the fastest possible speed and reach their minimum range at the same moment. The speed with
which the arms close is controlled by two restrictor fittings, one located on each cylinder at the rod end.
11. To complete installation, insert a hydraulic pressure gauge into the truck system's test port and adjust the
pressure relief setting. Never exceed maximum operating pressure for this clamp.
To equalize arm travel:
1) Close the arms from their full extension, watching to see which one is closing most rapidly.
2) Close the restrictor fitting on the cylinder controlling the faster arm until both arms are travelling at the same
rate. The clamp will probably have to be opened and closed several times to make this adjustment
accurately.
3) Close the restrictor fitting on the cylinder controlling the faster arm until both arms are travelling at the same
rate. The clamp will probably have to be opened and closed several times to make this adjustment
accurately.
12. To complete installation, insert a hydraulic pressure gauge into the truck system's test port and adjust the
pressure relief setting. Never exceed maximum operating pressure for this clamp.
REMOVAL OF SIDE SHIFT, FORKSPREADER OR CLAMP ATTACHMENTS

Removal is the reverse of the installation/assembly sequence noting all the safety precautions in par.1.
WARNING
Ensure that all locking devices are engaged upon assembly of attachment.
3 - 12
.
OPERATION OPERATION
OPERATION
MOUNTING/DISMOUNTING
CAUTION
Get on and off the lift truck only when it is at a complete standstill.
Never jump on or off the lift truck. It is extremely dangerous.
Do not hold to the control levers and steering wheel when getting on and off the lift truck.
Keep the handrails (assist grips) and step clean all the time, and repair damage, if any.
Do not use the handrails (assist grips) for any other purpose than getting on and off.
When getting on and off the lift truck, face the left side of the lift
truck that is at a complete standstill and support yourself securely
with handrails (assist grips) (1) and grip (2).
SEAT POSITION ADJUSTMENT

CAUTION
Adjust the seat position before getting on the lift truck, or at the time of operator change. (Carry out this adjustment only when
the lift truck is at a complete standstill.)
Adjust the seat position so that you can sufficiently depress the brake pedal while reclining yourself against the backrest.
(Carry out this adjustment only when the lift truck is at a complete standstill.)
Be sure to wear the safety seat belt while operating the lift truck.
1. Set the parking brake.

(See "TEMPORARY STOPPING AND PARKING (PAGE
3-24)".)
2. Take a seat and pull lever (1) to the left. (The operator's seat
can slide back and forth in this condition.)
3. Bring the operator's seat to the optimum position and release
lever (1). (It can be locked in this condition.)
4. After setting the seat, confirm that it is firmly locked by sliding
it forwards/backwards.
3 - 13
.
OPERATION OPERATION
METHOD OF ADJUSTING RECLINING ANGLE

(suspension seat only)
1. Pull up lever (1). (The backrest angle can be adjusted in this
condition.)
2. Adjust the backrest angle and release lever (1).
After adjusting, try to move the seat back and forth slightly to
make sure that the seat is securely locked.
METHOD OF ADJUSTING SUSPENSION

(suspension seat only)
1. Turn adjusting knob (1) located on the front right side of the
operator's seat to select suspension best suited to your weight.
Needle (2) indicating set weight swings to a heavier side if you
turn the knob to (B), and swings to a lighter side if you turn the
knob to (A).
(Weight adjustment range: 50 to 120 kg)
METHOD OF FITTING AND RELEASING SEAT BELT

1. Pull tongue (1) out of the safety seat belt holder located on the
right side of the operator's seat and push it into buckle (2) until
it is clicked into place. (The safety seat belt is locked in this
condition.)
The safety seat belt has such a mechanism that it senses a
shock and locks itself at the holder. For this characteristic, it
may be locked while the belt is tucked in the holder, though
quite rarely. If this happens, hold buckle (1) with both hands
firmly, give the belt a strong pull to loosen the belt and then pull
the belt out slowly.
2. To release the safety seat belt, hold tongue (1) with the left
hand and press red button (3) on buckle (2) with the right hand.
3. Then the belt is tucked into the holder automatically. While the
belt is being tucked in, hold tongue (1) so that the belt is tucked
in slowly.
3 - 14
.
OPERATION OPERATION
ADJUSTING POSITION OF STEERING WHEEL

CAUTION
Always stop the lift truck completely before adjusting the position of the steering wheel. After adjusting, move the steering wheel
backward and forward to check that it is locked securely in position.
1. Park the lift truck. (For details, see "TEMPORARY STOPPING

AND PARKING (PAGE 3-24)".)
2. Pull up lock lever (1). (In other words, move the lever to (A)
position.)
3. Move the steering wheel back and forth to select the optimum
position.
4. Pull down lock lever (1) (in other words, move the lever to (B)
position) and lock the steering wheel at the optimum position.
5. Try to move the steering wheel back and forth to be sure that
the it is firmly locked.
3 - 15
.
OPERATION OPERATION
STARTING LIFT TRUCK OFF

WARNING
Do not attempt to start up the engine by intentionally short-circuiting the engine startup circuit. Such a malpractice can cause a
serious personal injury and fire.
CAUTION
Before the startup, check the surroundings for safety and sound the horn.
Do not allow people to come near the lift truck while it is at work.
There is a blind spot at the rear of the lift truck, so take good care when backing it up.
When starting up the engine, move the forward / reverse lever and high / low lever to the neutral position, apply the parking
brake and depress the clutch pedal (inching pedal if it is a TORQFLOW transmission type).
STARTING ENGINE
CAUTION
When turning the starting switch ON, always sit in the operator's seat, set the directional lever to neutral, and keep your foot off
the accelerator pedal.
1. Move the forward / reverse lever and high / low lever to the
neutral position. (The engine starting motor is not actuated until
after the forward / reverse lever is in the neutral position.)
2. Pull the parking brake lever.
3 - 16
.
OPERATION OPERATION
3. Depress the clutch pedal in case of a clutch type lift truck. If it

is a TORQFLOW transmission type, depress the inching
pedal.
4. (1) Gasoline engine type: Turn the engine starting switch key
to the START position with the foot off the accelerator
pedal, and then the engine will start up.
Diesel engine type: When the engine starting switch key is
turned to the ON position, engine preheating starts, and in
8 seconds the glow indicator goes off, telling that
preheating has been finished.
When the engine starting switch key is turned to the START
position while the accelerator pedal is depressed slightly
(lightly), the engine will start up. If the engine is started while
still preheating, the preheating function is automatically
released.
Time required for preheating can vary depending on the
ambient temperature and engine coldness. Use the
following benchmark for preheating time.
12C (53.6F) --- Preheating not required
0C (32F) --- Several seconds
-20C (-4F) -- 8 seconds
(2) When the engine has started up, release the engine
starting switch key. (The key will automatically return to the
ON position.)
(3) Carry out a warming-up run.

Gasoline engine type: The auto choke senses the rising
engine cooling water temperature and automatically stops
the warming-up run.
Diesel engine type: Release the accelerator pedal and

continue with a warming-up run for a while.
NOTICE
Do not leave the engine starting switch key in the ON position while the engine is not running. The battery capacity goes down,
making it difficult to start up the engine.
Limit the use of the engine starting motor within 10 seconds and do not let it run continuously beyond 10 seconds.
Wait for another 20 seconds before using the engine starting motor again.
Do not turn the engine starting switch key to the START position while the engine is running.
3 - 17
.
OPERATION OPERATION
STARTING LIFT TRUCK OFF

NOTICE
Do not rest the foot on the clutch pedal, inching pedal and brake pedal except when so required.
Clutch type lift truck: Depress the clutch pedal and move forward
/ reverse lever (1) to the F or R position and
high / low lever (2) to the 1 position.
TORQFLOW transmission type lift truck: Depress the inching

pedal and move the
forward / reverse lever
to the F or R position.
CAUTION
When operating the control levers, be sure to depress the clutch pedal.
NOTICE
Always stop the lift truck completely before operating the lever to change the travel direction.
3 - 18
.
OPERATION OPERATION
FORWARD/REVERSE LEVER, HIGH/LOW SPEED LEVER (CLUTCH TYPE LIFT TRUCK)

REMARKS
The engine cannot be started if this lever is not at the N (neutral) position. (It is equipped with a neutral switch).
A type
Lever (1) acts to change a travel direction (forward / reverse) of the
lift truck.
F: Forward
N: Neutral
R: Reverse
Lever (2) acts to change the speed gears of the lift truck.
2: High speed
N: Neutral
1: Low speed
B type (option)
lift truck.
F: Forward
N: Neutral
R: Reverse
2: High speed
N: Neutral
1: Low speed
C type (option)
2: High speed
N: Neutral
1: Low speed

lift truck.
F: Forward
N: Neutral
R: Reverse
3 - 19
.
OPERATION OPERATION
FORWARD/REVERSE LEVER (TORQFLOW TRANSMISSION LIFT TRUCK)

This lever acts to change a travel direction (forward / reverse) of
the lift truck.
F: Forward
N: Neutral
R: Reverse
REMARKS
The engine cannot be started if this lever is not at the N (neutral)
position. (It is equipped with a neutral switch).
Release the parking brake and check that the direction of travel
and the area around the lift truck are safe.
Clutch type lift truck :

Depress the accelerator pedal slowly with your right foot while
releasing the clutch pedal slowly with your left foot.
TORQFLOW transmission lift truck :
Depress the accelerator pedal slowly with your right foot while
releasing the inching pedal slowly with your left foot.
REMARKS
If the clutch pedal or inching pedal are partially engaged, it is
possible to carry out inching.
If the lift truck is operated for a long time with the clutch kept in the
partially engaged condition, the truck incurs damage. So limit such
practice to the minimum (less than 10 seconds).
3 - 20
.
OPERATION OPERATION
SHIFTING GEAR (CLUTCH TYPE LIFT TRUCK)

Release the accelerator pedal and depress the clutch pedal at the
same time.
Shift the high/low speed control lever to position 2.

When it meshes, gradually release the clutch pedal while
depressing the accelerator pedal.
SHIFTING DIRECTION
NOTICE
Change the travel direction only after the lift truck comes to a complete stop.
Move the forward/reverse control lever from F to R.

In case of a clutch type lift truck, shift the gear shift lever to the 1st
gear.
Or move the forward/reverse control lever from R to F.

In case of a clutch type lift truck, shift the gear shift lever to the 1st
gear.
3 - 21
.
OPERATION OPERATION
STARTING AND INCHING ON INCLINE

CAUTION
Never carry out inching by depressing the accelerator pedal fully and then adjusting the amount the brake pedal is depressed.
1. When trying to start up the lift truck on an upslope, pull back

parking brake lever (1) first.
2. While gradually depressing accelerator pedal (4) (releasing the
clutch pedal in case of a clutch type), release parking brake
lever (1) slowly, allowing the lift truck to climb up the slope.
3. When the lift truck has gained some speed, release parking
brake lever (1) completely. Climbing speed can be controlled
by the amount of depressed accelerator pedal (4).
4. When slowing down or bringing the lift truck to a complete stop
on an upslope, release accelerator pedal (4) gradually
(depressing clutch pedal (2) simultaneously in case of a clutch
type) and depress brake pedal (3) right before the lift truck
stops.
(A): Location of clutch pedal in case of a clutch type
(B): Location of accelerator pedal in case of a torque converter
type
5. After stopping the lift truck, always pull parking brake lever (1)
fully.
3 - 22
.
OPERATION OPERATION
TURNING
CAUTION
Take care to avoid the outside of the counterweight hitting against objects when turning.
Operate steering wheel knob with the left hand.
When turning, keep to the inner side when advancing and outer
side when reversing, considering the properties of the rear steering
system.
NOTICE
If the lift truck is to be steered while stopped, a large steering force is
required.
In this case, depress the accelerator pedal slightly and operate the steering
wheel while inching, to allow it to be rotated smoothly.
3 - 23
.
OPERATION OPERATION
TEMPORARY STOPPING AND PARKING

CAUTION
Select a parking area well away from the driving area.
1. Clutch type lift truck :

Release the accelerator pedal, depress brake pedal (1), then
depress clutch pedal (2) immediately before the lift truck stops.
TORQFLOW transmission lift truck :
Release the accelerator pedal, then depress brake pedal (1).
2. After the lift truck comes to a stop, apply the parking brake by pulling parking brake lever (3). After it stops
completely, move the forward / reverse lever and high / low lever (in case of clutch type) to the neutral position.
3. Return forward/reverse control lever (4) to the neutral position.
PARKING BRAKE LEVER

Locking position: The parking brake can be applied in this position.
When the parking brake lever is pulled back, the
parking brake is applied, locking the front
wheels. Use this locking function to temporarily
stop or park the lift truck.
Free position: The parking brake is released in this position. When
releasing the parking brake, press a button on top of
the lever, releasing a hook, and return the lever to
the free position.
WHEN LEAVING THE LIFT TRUCK UNATTENDED

When leaving the lift truck, always perform the following procedure.
1. Lower the forks to the ground.
2. Tilt the mast full forward.
3. Turn the starting key to the OFF position, then remove the key.
(When it is in the OFF position, the engine starting switch key
can be inserted and pulled out and all the electric circuits are
switched off except for the horn and lamps.)
4. Check that the parking brake lever is pulled back.
3 - 24
.
OPERATION OPERATION
FORK SPREAD ADJUSTMENT

CAUTION
Take extreme care not to get hands or fingers caught while moving the forks.
1. Move the lift truck in front of the load, and stop.

2. Position the mast vertically and lift the forks 10cm (4 in) above
the ground.
3. Tilt the mast forward.
4. Pull up the knob of the fork stopper and turn it 90 to the FREE
position. (In this condition, the forks can be moved to the left
or right.)
5. Adjust the fork spread corresponding to the load size so that
the load center of gravity coincides with the center of the lift
truck.
6. Set the mast vertical, lower the knob, and turn the fork stopper
90 to the LOCK position. (In this condition, the forks are
locked in position.)
7. After the adjustment, check that the fork is secured with the
fork stopper. If it is not secured, there is the danger that the fork
freely moves sideways, while the lift truck is running, and lets
fall the cargo.
3 - 25
.
OPERATION OPERATION
LOAD HANDLING OPERATION
PICKING UP
LIFT CONTROL LEVER
CAUTION
Sit in the operator's seat and check that the surrounding area is safe before
operating the lift lever.
This is a lever with which to raise or lower the fork.

Lower: Push the lever forward.
Raise: Pull the lever back.
REMARKS
The fork rising speed varies as the lever is pulled back further and as the accelerator pedal is depressed harder.
The fork falling speed varies as the lever is pushed forward further.
TILT CONTROL LEVER
CAUTION
Sit in the operator's seat and check that the surrounding area is safe before
operating the tilt lever.
This is a lever with which to tilt the mast back and forth.
Tilt forth: Push the lever forward.
Tilt back: Pull the lever back.
REMARKS
The speed when tilting the mast forward or back can be controlled by the amount that the lever is operated and the
amount that accelerator pedal is depressed.
1. Insert the fork up to the bottom.

2. If the fork cannot be inserted up to the bottom at one go, drive
the lift truck forward until the fork is inserted into a pallet by 2/3
to 3/4 of the fork length and lift the load by 5 - 10 cm (2 - 4 in)
off the floor.
Then drive the lift truck backward by 10 - 20 cm (4 - 8 in) , lower
the load on the floor once and then drive the lift truck once
again until the fork is inserted up to the bottom.
3 - 26
.
OPERATION OPERATION
3. Raise the load 5 - 10 cm (2 - 4 in) and reverse the lift truck to

a position where the load can be lowered.
4. Lower the load to the height of 15 - 20 cm (6 - 8 in) above the

ground and tilt the mast back.
STACKING
1. Stand the mast vertically and lift forks 5 - 10 cm (2 - 4 in) past
the stacking position. Advance the lift truck slowly.
2. Lower the load once to the desired place.
3. Pull the fork out of the pallet by as much as 10 - 20 cm (4 - 8 in)

by backing up the lift truck. Then raise the load again by as
much as 5 - 10 cm (2 - 4 in), move it to a right stacking spot,
lower it on the floor and slowly back up the lift truck until the fork
is completely pulled out.
3 - 27
.
OPERATION OPERATION
COMBINATION SWITCH OPERATION
LIGHTING SWITCH
This is a switch to switch on the front lamps.
Position 1 (OFF): Parking lamp (side clearance lamp) and front
lamps are OFF
Position 2 : Parking lamp (side clearance lamp) lights up
Position 3 : Parking lamp (side clearance lamp) stays lighted up,
and front lamp lights up
TURN SIGNAL SWITCH

This is a switch to flash the turning signal lamps.
Left turn (L) : Push lever forward

Right turn (R): Pull lever back
REMARKS
This lever has an auto-return mechanism, so it will return to neutral
position (N) when the steering wheel is turned back.
3 - 28
.
OPERATION COLD WEATHER OPERATION
COLD WEATHER OPERATION

PREPARATIONS FOR LOW TEMPERATURE
If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows.
FUEL AND LUBRICANTS, HYDRAULIC OIL

Change fuel and lubrication oil for all the components to a lower viscosity type. For the designated viscosity, refer
to "LUBRICANT LIST (PAGE 4-17)".
COOLANT
CAUTION
Coolant is flammable, so keep it away from open flame.
Never smoke when handling coolant.
NOTICE
When the truck is shipped out from the factory, it is filled with low-emission type (non-amine type) long life coolant. It may be used
in the ambient temperature as low as -20C, unless otherwise instructed.
Precautions when handling coolant

Coolants are commonly used after being diluted. When diluting coolants, use distilled water or tap water.
Check that there is no leakage of water from the radiator, water pump, or hoses.
Drain all coolant and flush the inside of the system before adding new coolant.
Do not mix the low- emission type coolant with other conventional ones for use in the truck.
LONG LIFE COOLANT (FAF-NAC)

Dilution
Use dilution commensurate with the environment in which the lift truck is operated. Take note, however, that the
allowable lowest dilution is 30%, so be sure to use dilution higher than that.
Min.temperature (C) -10 -15 -20 -25 -30 -35 -40 -45 -50
Dilution (%) 30 36 41 46 50 54 58 61 64
Dilution in the table allows for approx. 2% safety margin as against the standard values.
If dilution exceeds 65%, freezing temperature rises conversely. Be careful not to add too much coolant.
BATTERY
When the ambient temperature drops, the capacity of the battery will also drop. If the battery charge is low, the
battery electrolyte may freeze.
Maintain the charging rate above 75%, and protect the battery from cold temperatures for an easy startup in the
morning.
If distilled water is to be added, to prevent freezing, wait until before starting operations the next morning before
adding the distilled water.
3 - 29
.
COLD WEATHER OPERATION OPERATION
PRECAUTIONS AFTER COMPLETION OF OPERATIONS
DRAIN WATER
Drain any water accumulated in the fuel tank to prevent the water from freezing during the night.
ADD FUEL
To prevent moisture from collecting inside the fuel tank, always fill the fuel tank after completing operations.
3 - 30
.
OPERATION ACTIONS IN ENGINE OVERHEATING
ACTIONS IN ENGINE OVERHEATING

ACTION WHEN ENGINE HAS OVERHEATED
CAUTION
If your remove the radiator cap in an attempt to hurriedly cool the radiator, steam will spurt out. Never try to remove the cap before
the engine cools down sufficiently.
If the engine cooling water temperature gauge comes with the overheat range, move the lift truck to a safe place to
park and take the following actions.
1. Keep the engine running at low idling, open the engine hood for better airing of the engine room and wait for the
engine to cool down.
Should the radiator cooling fan be not turning, stop the engine immediately and let the engine cool down.
2. Stop the engine, after checking the coolant temperature gauge and being satisfied that the coolant temperature
has dropped sufficiently.
3. Check out the coolant level and water leakage from the radiator or radiator hose, only after the engine has
sufficiently cooled down.
4. If the cooling water is short, fill the radiator and sub-tank with additional water. Should water leakage be found,
stop the use of the lift truck and call your Komatsu Forklift distributor.
CLEANING INSIDE OF COOLING SYSTEM

If scales or rust are found in the cooling system, clean the radiator with detergent to make sure that clean water
always circulates in the system.
CLEAN RADIATOR FINS
CAUTION
Dirt may fly and get into your eyes, so always wear protective glasses or goggles.
If the radiator fins are clogged, it will cause overheating, so blow

the radiator fins with compressed air, steam, or water.
When using air or steam, always point the nozzle at a right angle
to the radiator when cleaning.
Air pressure:0.98 MPa (10 kgf/cm2)

Steam pressure:0.39 MPa (4 kgf/cm2)
CHECK FAN BELT TENSION

If the fan belt is loose, adjust it to the specified tension.
3 - 31
.
LONG-TERM STORAGE OPERATION
LONG-TERM STORAGE
BEFORE STORAGE
NOTICE
If it must unavoidably be left outdoors, park the lift truck on flat ground and cover it with a tarpaulin.
If the lift truck is going to be out of service for a long period, store it in the following manner.
Store it in an indoor dry parking area after washing and cleaning each part.
Completely lubricate and change the oil.
Apply a thin coating of grease to metal surfaces of hydraulic piston rods.
Disconnect the negative (-) cable of the battery, and then either cover it or take down and store it indoors.
If the temperature drops below 0 C, add anti-freeze to the cooling water.
DURING STORAGE
CAUTION
If it is necessary to carry out the rust prevention operation while the lift truck is indoors, open the doors and windows to improve
ventilation and prevent gas poisoning.
RUST PREVENTION OPERATION

Operate the engine and move the lift truck for a short distance once a month so that a new film of oil will coated
over lubricated surfaces. This prevents loss of the oil film over the long period of storage.
Before operating the work equipment, wipe off the coat of grease from the hydraulic cylinders.
Charging battery
Batteries discharge naturally even though they are not used but left unattended. Charge the battery once a
month.
AFTER STORAGE
Remove the drain plugs from the oil pan and each case, and drain out the water.
Wipe off the grease from the hydraulic cylinder rods.
After starting the engine, carry out the warming-up operation until the engine oil pressure warning lamp goes out
in order to settle all the parts thoroughly.
3 - 32
.
OPERATION TRANSPORTATION
TRANSPORTATION
DIMENSIONS
For truck dimensions, refer to the Standard Specifications Sheet(s).
WEIGHTS
For truck weight refer to the Standard Specifications Sheet(s).
CENTRE OF GRAVITY
Refer to Figure 1. for the centre of gravity of the Front lift. For further information or regarding center of gravity,
contract the manufacturer or trained manufacturer representative.
3 - 33
.
TRANSPORTATION OPERATION
SECURING TRUCK
CAUTION
It is recommended that the transporting of the truck by road, rail or sea, may only be undertaken by an authorized transport
company.
All truck being transported by road, rail, or sea have a common method of stowage, which reduces the possibility
of damage to the truck and paintwork.
The chassis will be secured to the deck of the lorry, rail truck or ship by means of chains from the chassis lifting eyes
to a convenient desk bolt. All four corners of the chassis will be secured, preferably with adjust screws, to ensure
that the chains are in under tension, see Figure 2.
The chassis will be secured with the mast tilt in the fully back position.
3 - 34
.
Securing of Mast
Where machine are being transported with the mast fitted into the truck, no action is required. When it is necessary
to remove the mast during transportation the following procedure will be undertaken:
1. Remove forks from carriage and action, as securing of forks below.

2. Remove mast and carriage assembly from truck.
3. Weld securing bar across bottom of mast and carriage, to prevent movement of mast and carriage assembly of
where holes are available, fit bolt though masts and carriage, and retain with a nut-refer to Fi.3.
Where possible, and in particular with high lift masts, the lift chain is to lightly banded to the lift cylinder, at not
less than 1 meter intervals to ensure that the chain does not slap during transportation.
Trick card of rubber is to be laid between the chain and the lift cylinder, and all around the cylinder where banding
is taking place, to protect the paintwork.
Where it is impracticable to retain the chain as above, the free end id to be wired to a suitable position, and care
taken to ensure paintwork is not damaged during transportation.
NOTICE
Other than the welding specified Fig.3, no welding is to take place on the carriage and the mast channels.
Securing Forks
Each pair of forks will be securely bended together using banding
material as show in Fig.4
3 - 35
.
TRANSPORTATION OPERATION
Securing Forks - Mast Assembly in Truck

The forks having been handed together will be offered up to the mast/carriage assembly and laid on the fork stowage
brackets which would have been previously hooked onto the carriage. The assembly will then be securely banded
to the carriage, see Fig.5
Securing Fork - Mast Assembly Out of Truck

The forks having been banded together will be offered up to the mast/carriage assembly.
Banding material is passed under the mast channels and over the forks, and securely connected, see Fig.6.
NOTICE
When welding to any part of the assembled truck, ensure that the batteries and alternator are disconnected.
After welding has been completed, spray all bare metal and welding preservatives.
3 - 36
.
ELECTRICAL AND HYDRAULIC CONNECTIONS

All electrical and hydraulic connections which are lift disconnected are to be plugged.
SLINGING
Some of the suitable lifting point for the truck are indicated by the crane hook label shown in figure seven; these
lifting points are situated on the mast and counterweight
For further information or advice regarding suitable lift for the truck contact the manufacturer or their authorized
representative.
NOTICE
Ensure that all lifting tackle has a Safe Wiring Load (S.W.L) suitable for the truck unladed weight.
Before any lifting attempt is made, check that the mast is in the vertical position.
Lifting the truck

Attach suitable lifting tackle to the trucks points.
1. Place packing material to avoid damage to truck finish, where

lifting tackle is likely to contact track.
2. Take up the slack and stand clear of the truck.
3. Make a test lift, just clear of the ground, to ensure that the lift is
square and even, if not lower to ground and adjust lifting tackle
as required.
4. If the above are all correct then proceed with the lift of the truck
to the required position, with slow and definite movements.
5. Lower to the required position and remove lifting tackle.
3 - 37
.
.
MAINTENANCE
4-1
.
CHECK BEFORE OPERATION MAINTENANCE
CHECK BEFORE OPERATION

CAUTION
Never operate the lift truck before the check before operation is completed.
If any abnormality is found during checking, immediately consult a Komatsu Forklift distributor and do not operate the lift truck
until repaired.
Oil leakage can cause a lift truck fire.
CHECK BEFORE OPERATION (WITH KEY SWITCH OFF)
CHECK ABNORMALITIES FOUND ON PREVIOUS DAY

Re-check any repaired part which was found to be faulty during the previous day's checking and operation of the
lift truck.
CHECK FOR OIL LEAKAGE AND BATTERY FLUID LEAKAGE

Go around the lift truck once for inspection.
Look under the lift truck to check that there is no oil or water
leakage.
CHECK FOR CRACKS AND DAMAGE

Carry out a visual inspection for a crack and damage. Pay attention
to the following items in particular then.
Head guard
Fork
Fork backrest
Fork carriage
Mast
Fuel tank
Hydraulic oil tank
4-2
.
MAINTENANCE CHECK BEFORE OPERATION
CHECK TIRES AND RIMS

Check that the tire inflation pressure is correct.
For the correct tire pressure, refer to "SERVICE DATA (PAGE

4-32)".
Check the hub nuts for loosening.
NOTICE
Tighten the hub nuts to the specified torque. (For tightening torque see "SERVICE DATA (PAGE 4-32)".)
Check the tires for excessive wear, damage, and adhesion of foreign matter.
Check the rims for deformation or damage.
CHECK IN ENGINE ROOM
CAUTION
Be careful not to get your hand caught when opening or closing the hood.
METHOD OF OPENING ENGINE HOOD

1. Push up lever (1) on the front left side of the engine hood with
the left hand.
2. Push up the engine hood until engine hood stopper (2) is set.
4-3
.
METHOD OF CLOSING ENGINE HOOD

1. Push in the red stopper (stamped as "PRESS"), and then lower
the engine hood slowly with the right hand until it is securely
locked.
CHECK OIL LEVEL IN HYDRAULIC TANK

1. Lower the forks fully to the floor and stand the mast vertically
(perform on flat floor).
2. Open the engine hood and remove the dipstick (combined with
breather) on the right side of the lift truck.
3. Wipe off hydraulic oil with a clean cloth and insert dipstick into
the tank.
4. Pull out the oil level gauge again and check that the stuck oil is
within the normal range.
5. Refill with hydraulic oil if it is short. If the oil is spilt then, wipe it
off without fail.
NOTICE
Always use Komatsu Forklift genuine hydraulic oil.
CHECK OIL LEVEL IN ENGINE OIL PAN

Check with the oil level gauge that the engine oil level is within the
normal range. Refill if it is short.
NOTICE
When the engine oil is considerably contaminated or has been
discolored, replace with new oil.
For the replacement engine oil, be sure to use genuine engine oil of
Komatsu Forklift.
4-4
.
CHECK OIL LEVEL IN BRAKE RESERVOIR TANK
CAUTION
Always use Komatsu Forklift genuine brake fluid for the brake fluid.
If the oil level in brake oil reservoir tank (1) is within the normal
range, then the amount of oil is adequate. If it is short, refill with
genuine brake oil of Komatsu Forklift.
CHECK BATTERY ELECTROLYTE LEVEL
CAUTION
First aid when you have spilt battery electrolyte on yourself
If you have spilt battery electrolyte on your clothes or skin, immediately shed the clothes and flush the part with a large quantity
of tap water. and then consult a doctor. In particular, should battery electrolyte get into your eyes, flush them immediately with
fresh tap water for 10 to 15 minutes and then consult a doctor at once.
Do not cause short-circuiting or sparking in the electric circuit. In addition, never bring the battery to fire like a lit cigarette.
Wear goggles, protective gloves and rubber-soled shoes during the inspection and maintenance work of the battery.
When the battery electrolyte level is not within the normal range,
refill with distilled water up to upper limit line (A).
Wipe out the battery cap breather and battery terminals.
NOTICE
If the battery electrolyte has spilled and the level has gone down, have
your battery repair shop add dilute sulphuric acid of the same density.
Do not use a metal funnel when adding distilled water or dilute sulphuric
acid.
4-5
.
CHECK COOLANT LEVEL
CAUTION
Carry out a regular inspection of the coolant level through the sub-tank before beginning the day's work when the engine is still
cold.
When the coolant temperature is still high, do not try to remove the radiator cap or sub-tank cap. Steam or boiling water may
spurt out, causing burns.
When removing the radiator cap after the coolant temperature has gone down, turn the cap slowly to release the pressure
before removing it.
NOTICE
Even if the coolant level in the sub-tank seems normal, check the coolant
level inside the radiator every month or ever 200 hours of hour meter
reading according to the maintenance schedule. If the coolant level inside
the radiator is lower than specified, that may invite an engine overheating
problem.
Check the radiator and radiator hose for any water leakage.
If cooling water in the sub-tank is not within the normal range when
it is still cold, refill with fresh water up to "FULL" level.
When the cooling water in the sub-tank runs short, refill the radiator
tank and sub-tank.
CHECK DEFLECTION OF V-BELT

For the inspection of V belt tension, depress the belt center with
force of 98 N (10 kgf).
For the inspection of V belt deflection, refer to "SERVICE DATA
(PAGE 4-32)".
NOTICE
Replace the belt if the belt is stretched and there is no allowance for adjustment, or if the belt is cut or cracked.
4-6
.
OPERATE FROM OPERATOR'S COMPARTMENT

Inspection item of brake pedal
Amount of play
Height of pedal (h) when depressed
Inspection item of clutch pedal (clutch type lift truck)
Amount of play
Inspection item of inching pedal (torque converter type lift truck)
Amount of play
Interconnected stroke
For the standard value of each inspection item above, refer to

"SERVICE DATA (PAGE 4-32)".
CHECK PARKING BRAKE

NOTICE
If the standard value of the parking brake lever operating effort is not within
the normal range, call your Komatsu Forklift distributor.
Check that the operating effort of the parking brake lever is normal.
For the standard value of the parking brake lever operating effort,
see "SERVICE DATA (PAGE 4-32)".
If the lift truck is installed with a parking brake warning buzzer

(optional), check that the buzzer begins to sound when leaving the
truck with the parking brake left in the released condition.
CHECK HORN
Press the horn button and check that the horn sounds normally.
4-7
.
CHECK AFTER STARTING (WITH STARTING SWITCH ON)

NOTICE
Proceed to the following inspection after reading "MOUNTING/DISMOUNTING (PAGE 3-13)", "SEAT POSITION ADJUSTMENT
(PAGE 3-13)" and "STARTING LIFT TRUCK OFF (PAGE 3-16)".
CHECK FOR ABNORMAL NOISE, ABNORMAL VIBRATION

Check in particular that there is no abnormal noise or abnormal vibration from the engine or hydraulic pump.
CHECK ENGINE EXHAUST GAS COLOR

Check that the engine exhaust gas color is normal.
Colorless: Normal
Black: Incomplete combustion
White: Engine oil scraped up or scraped down
CHECK FUEL LEVEL IN FUEL TANK
CAUTION
When adding fuel, never let the fuel overflow. This may cause a fire. If you spill fuel, thoroughly clean up any spillage.
NOTICE
Never use fuel mixed with kerosene, as such a malpractice causes damage to the fuel injection system.
When fuel level gauge needle points to (A), the fuel tank is full.
If it is short, stop the engine and refill the fuel tank to the full
through the fuel filler port.
For the right fuel, refer to "LUBRICANT LIST (PAGE 4-16)".
When refilling, remove dirt in and around the filler port cap as
precautions so that dirt will not get into the fuel tank.
After refilling, tighten the filler port cap securely and wipe off spilt
fuel without fail.
4-8
.
CHECKS USING GAUGES AND WARNING LAMPS
ENGINE OIL PRESSURE WARNING LAMP, CHARGE WARNING LAMP, LIFTING INTERLOCK DISPLAY LAMP, MAINTENANCE
LAMP
NEUTRAL INDICATOR LAMP

ENGINE WATER TEMPERATURE GAUGE

The indicator should be in the white range.
4-9
.
SEDIMENTER WARNING LAMP

(Diesel powered lift truck)
The lamp is in a normal condition if it lights up when the starting
switch is turned ON and goes off after the engine startup.
If the lamp remains lighted even after engine startup, drain water
from the sedimenter. (For draining water, refer to "DIESEL
ENGINE (PAGE 4-20)")
CHECK STEERING WHEEL

Check the following points.
Play (the play should be 10 - 30 mm (0.4 - 1.2 in)).
There must be no up-down play.
CHECK LAMPS
Check that the front lamps, parking lamps (clearance lamps), brake lamps and backup lamps work normally and that
none of them is either smeared or damaged.
CHECK REARVIEW MIRROR

The mirror is set at such an angle that it enables the operator to
see the rear easily.
The mirror is free of smear or damage.
CHECK BUCKUP BUZZER
CAUTION
Move the HI / Lo lever (clutch type lift truck) to the neutral position, pull back the parking brake lever and depress the clutch pedal
(inching pedal in case of a torque converter type lift truck), and then carry out this inspection.
Check that the backup buzzer sounds when the forward/reverse control lever is set to the REVERSE position.
If the backup buzzer does not sound when the forward/reverse control lever is set to the REVERSE position, carry
out repairs or replacement immediately.
4 - 10
.
CHECK LIFT CHAIN TENSION
CAUTION
Move the forward / reverse lever to the neutral position, and then carry
out this inspection.
Do not put the foot under the fork.
1. Raise the fork from the ground.

Lift amount "A": 10 - 15 cm (4 - 6 in)
2. Check the right and left deflections of the lift chain by pressing it at the center.
The tension is normal when both deflections are approximately equal.
3. If the deflections differ from each other,adjust with the nut of the lift-chain stopper bolt.
NOTICE
Make sure that the chain tension is the same on the left and right.
If the tension is not the same, the load will be unevenly balanced even if it is set in the center of the lift truck, and there is danger
that the chain may break or the lift truck may tip over.
CHECK ELONGATION OF THE LIFT CHAIN
CAUTION
Move the forward / reverse lever to the neutral position, and then carry
out this inspection.
Do not put the foot under the fork.
NOTICE
If the measurement value exceeds this range, replace the chain.
Measure the length over 17 links and check that the length is within
the specified value.
For the standard length over 17 links, see "SERVICE DATA
(PAGE 4-32)".
CHECK THE LIFT CHAIN LUBRICANT
CAUTION
When a lift chain gets rusted, it easily breaks. In order to prevent them from getting rusted, coat engine oil on them a bit earlier
than normal.
Inspect the lift chains visually for damage and cracks. If any abnormality has been found with them, call your Komatsu Forklift
distributor, asking for prompt replacement.
If the lift chains are poorly lubricated, coat engine oil on them anew.
NOTICE
Use Komatsu Forklift genuine engine oil.
(See "LUBRICANT LIST (PAGE 4-16)".)
4 - 11
.
CHECK WHILE ADVANCING SLOWLY
CHECK STEERING WHEEL OPERATION

Check the following items while advancing slowly.
No deviation of steering wheel.
No unstable steering in straight drive.
No feeling of abnormally-heavy steering when the steering wheel is turned.
CHECK OF BRAKE OPERATION

Check the following by depressing the brake pedal to apply the brakes while running the truck slowly.
The brakes work satisfactorily.
The brakes do not have an uneven action.
CHECK OPERATION OF INCHING PEDAL (TORQFLOW TRANSMISSION LIFT TRUCK)

Depress the pedal slightly (partially engage the clutch) and check that it is possible to carry out inching.
Check that the lift truck stops when the pedal is completely depressed.
CHECK FOR ABNORMAL SOUND OR ODOR

Check that no abnormal sound or odor is generated while advancing slowly.
CHECK OF WORK EQUIPMENT OPERATION
CHECK THE WORK EQUIPMENT OPERATION

Check that the forks lift and lower smoothly and the mast tilts forward and backward smoothly during operation of
the work equipment lever from the operator seat.
NOTICE
If there is any abnormality, please contact your Komatsu Forklift distributor immediately.
CHECK FOR ABNORMAL SOUND OR ODOR

Check that no abnormal sound or odor is produced while operating the work equipment from the operator seat.
4 - 12
.
MAINTENANCE CHECK AFTER OPERATION
CHECK AFTER OPERATION

After all the above inspections have been finished and each part of the lift truck is cleaned, and before it is stored,
carry out the following inspections.
1. Oil leakage or battery fluid leakage from the units.
2. Cracks or damage.
3. Check faults found during operation and report them to the person responsible for the lift truck.
4. Lubricate the units (if necessary).
4 - 13
.
OUTLINE OF SERVICE MAINTENANCE
OUTLINE OF SERVICE
For replacement, use genuine spare parts of Komatsu Forklift.
When changing or adding oil, do not use a different type of oil.
Unless otherwise specified, the oil and coolant used at delivery from the factory shall be as shown in the table
below.
1)Tank, cases
Item Type of fluid

Differential case SAE90GL5
Hydraulic tank SAE10WCD
TORQFLOW transmission case SAE10WCD
Use specified on higher grade oil
2) Cooling system
Fresh water + long life coolant
(This dilution is applicable to the ambient temperature as low as -20C.)
SUITABLE OIL
OIL
Since the oil is used for the work equipment, etc., under severe conditions (at high temperature and high
pressure), it will deteriorate as the operation time passes.
Always use an oil matching the grade and working temperatures given in the operation manual.
Always replace oil at the specified period even if not deteriorated.
Oil is often likened to human blood.
A lift truck should be maintained with the same care taken for the human body so that impurities (water, metal
chips, dust etc.) do not enter the lift truck system.
Most lift truck malfunctions are caused by entry of impurities.
Take special care to avoid entry of impurities during storage and lubrication, etc.
Never blend oils of different grades or brands.
Add specified volume of oil. Insufficient or excessive amounts of oil may both cause problems.
If the hydraulic oil in the work equipment has become murky, there is a possibility that either air or water entered
into the circuit. In that case, call your Komatsu Forklift distributor for their advice.
When replacing oil, replace the relevant filters at the same time.
GREASE
Grease prevents the generation of squeaking or noise from the joints, etc.
Nipples which are not listed in the section of "MAINTENANCE" do not have to be greased, as they are those for
overhauling. If a specific part develops stiff after a long period of use, then grease it.
After greasing, wipe off old grease forced out, especially on rotating parts that will be worn by adhering sand and
dirt.
OIL STORAGE AND PRESERVATION

Store and preserve oil so as not to allow entry of any water or dust.
When storing oil drums for long periods, place them side by side with the filler sides facing in the same direction.
If necessary to store outdoors, cover them with waterproof sheets.
To prevent deterioration during long-term storage, use drums on a "first in, first out" basis.
4 - 14
.
MAINTENANCE OUTLINE OF SERVICE
FILTERS
Filters are very important safety items which prevent problems caused by impurities contained in the oil or
hydraulic circuit which sends oil into important units. Periodically replace the filters referring to this manual.
When replacing oil filters, check for metal powder accumulated on the used filters.
Do not unpack replacement filters until immediately before installation.
Always use Komatsu Forklift genuine filters.
4 - 15
.
LUBRICANT LIST MAINTENANCE
LUBRICANT LIST
OIL AND GREASING CHART (OIL, GREASE LOCATIONS AND INSPECTION AND
MAINTENANCE INTERVALS)
U: Check and add fluid if necessary

: Change or add oil Symbol Type of fluid
: Shows the number of places to add oil or grease
Diesel engine oil
EO
Gasoline engine oil
MO Engine oil
GO Gear oil
HO Hydraulic oil
BF Brake fluid
G Grease
4 - 16
.
MAINTENANCE LUBRICANT LIST
LUBRICANT LIST
Engine oil pan Cooling system

Gasoline Diesel TORQFLOW Gasoline Diesel
Capacity Brake
engine engine transmission Differential Hydraulic engine engine
[l, 4D92E,
case
case tank
Fuel tank reservoir
4D92E,
(US gal, UK gal)] K15, 4D94LE, (incl. torque tank K15,
4D94LE,
K20, K25 converter) K21, K25
4D98E 4D98E
4.5 40 40
1 - 1.75 ton
(1.19, 0.99) (10.57, 8.80) (10.57, 8.80)
55 58
2 - 3 ton 3.8 7.5 6.0 0.15 9.1 9.2
9.6 (14.53, 12.10) (15.32, 12.76)
(1.0, (1.98, (1.59, 1.32) (0.04, (2.40, (2.43,
2 - 3 ton (2.54, 2.11) 50 37
0.84) 1.65) (3 ton std.) 0.03) 2.00) 2.02)
(L) (13.21, 11.00) (9.78, 8.14)
5.8
2 - 3 ton 40 40
(1.53, 1.28)
(N) (10.57, 8.80) (10.57, 8.80)
NOTICE
Never use fuel mixed with kerosene as such a malpractice can damage the fuel injection system much earlier than life.
For replacement lubricants, be sure to always use the genuine products of Komatsu Forklift. (The genuine oils, grease and
antifreeze are available at your distributor of Komatsu Forklift.)
CAUTION
Never use the wrong type of brake fluid.
4 - 17
.
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS MAINTENANCE
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

To ensure safety at all times when operating or driving the lift truck, the lift truck user must always carry out periodic
maintenance. In addition, to further improve safety, the user should also perform periodic replacement of parts given
in the table below. These parts in particular are closely related to safety and fire prevention.
The material of these parts may change over time, or may easily wear or deteriorate. However, as it is difficult to
judge the condition of the parts simply by periodic maintenance, they should always be replaced after a fixed time
has passed, regardless of their condition. This is necessary to ensure that their full function is always maintained.
However, if these parts show any abnormality before the replacement interval has passed, they should be repaired
or replaced immediately.
If the hose clamps show any sign of deterioration such as deformation or cracking, replace them at the same time
as the hoses.
Note that the periodic replacement is not covered by warranty.
IMPORTANT PARTS LIST
No. Part name Years elapsed

1 Master cylinder, wheel cylinder cup and dust seal, etc. 1
2 Rubber parts for brake booster 1
3 Brake hose or tube 2
4 Reservoir tank, tube 2
5 Power steering hose 2
6 Stop lamp switch (hydraulic type) 2
7 Fuel hose 2
8 Rubber parts inside power steering system 2
9 Lift chain 3
10 Hydraulic hose (for travel, loading & unloading and torque converter) 2
4 - 18
.
MAINTENANCE MAINTENANCE
MAINTENANCE
NOTICE
For any item of maintenance that you are not suppoted to do, ask your Komatsu Forklift distributor.
MAINTENANCE OF ENGINE
CAUTION
When carrying out maintenance of the engine, stop the engine and wait for it to cool down fully before starting.
GASOLINE ENGINE
1. CHANGE ENGINE OIL
1) Complate one cycle of the adjustment mode with the mode
button.Remove the drain plug, drain the oil, then tighten
the plug again.
2) Remove the dipstick.
3) Add the specified amount of engine oil.
4) Check the oil level with the dipstick.
For the right amount of replacement engine oil, refer to

"LUBRICANT LIST (PAGE 4-17)".
2. REPLACE ENGINE OIL FILTER

1) Using a filter wrench, remove the cartridge.
2) Clean the filter holder, coat the thread and the seal of the
new cartridge with engine oil, then install.
NOTICE
After installing the cartridge, start the engine and check that there is no
leakage of oil from the filter mount surface.
3. REPLACE FUEL FILTER

1) Loosen the nut and remove the cover to take out the filter element.
2) Clean off any carbon stuck to the tip of the plug or the surrounding Drain the water and clean out the dirt
accumulated at the bottom.
3) Install the new filter.
NOTICE
If any damage is found on the packing for the cover, replace it with a new one.
After replacing the defective packing, check that there is no fuel leakage from the hose mounting portion.
4 - 19
.
4. CHECK SPARK PLUG

1) Remove the plug using the plug wrench supplied with the
lift truck.
2) Clean off any carbon stuck to the tip of the plug or the
surrounding area.
3) Measure gap (A) with a plug gap gauge.
For the right type of plug in use, refer to "SERVICE DATA

(PAGE 4-32)".
DIESEL ENGINE
1. CHANGE ENGINE OIL
1) Remove the drain plug, drain the oil, then tighten the plug
again.
2) Remove the dipstick.
3) Add the specified amount of engine oil.
4) Check the oil level with the dipstick.

2. REPLACE ENGINE OIL FILTER

2) Clean the filter holder, coat the thread and the seal of the
new cartridge with engine oil, then install.
NOTICE
After installing the cartridge, start the engine and check that there is no
leakage of oil from the filter mount surface.
3. DRAIN WATER FROM FUEL FILTER

1) Loosen the combination sensor plug and drain the water
and sediment accumulated at the bottom.
NOTICE
Fuel is drained out at the same time, so prepare a container to catch it.
Always be sure to wipe up any spilled fuel.
4 - 20
.
4. REPLACE FUEL FILTER

1) Remove the combination sensor plug at the bottom of the
cartridge.
3) Install the combination sensor plug to the new cartridge.
4) Loosen plug (A) and move knob (B) up and down until after
no more air bubbles come out.
5) Tighten Plug (A)
4 - 21
.
CLEAN, REPLACE AIR CLEANER ELEMENT

CAUTION
Never clean or replace the air cleaner while the engine is running.
If compressed air is used to clean the element, dust will fly and there is danger that it may get into your eyes, so always wear
safety goggles.
CLEAN AIR CLEANER ELEMENT

NOTICE
If oil, grease, or carbon are stuck to the element, clean the element with special element cleaner.
Follow the instructions given with the cleaner.
In heavy-duty operating environment or conditions, clean and replace the element sooner.
CLEANING
1. Remove the element,blow the element from the inside with dry
compressed air at 0.68 MPa (7 kgf/cm2) and clean the whole
circumference.
2. After cleaning the element, insert the element parallel to the
body in inner part, then install the cover.
TESTING
Check visually that there is no damage to the element.
REPLACE AIR CLEANER ELEMENT

1. Remove the element.
2. Cover the air connector end with a clean cloth or tape.
3. Clean the inside of the body, then remove the cover fitted in
Step 2.
4. Insert a new element parallel to the body in inner part, then
install the cover.
4 - 22
.
CHECK BATTERY ELECTROLYTE SPECIFIC GRAVITY

CAUTION
Cautions when handling battery
First aid when you have spilt battery electrolyte on yourself
If you have spilt battery electrolyte on your clothes or skin, immediately shed the clothes and flush the part with a large quantity
of tap water. and then consult a doctor. In particular, should battery electrolyte get into your eyes, flush them immediately with
fresh tap water for 10 to 15 minutes and then consult a doctor at once.
Strict prohibition of fire
Do not cause short-circuiting or sparking in the electric circuit. In addition, never bring the battery to fire like a lit cigarette.
CHECK BATTERY ELECTROLYTE SPECIFIC GRAVITY

1. Charge the battery, and after charging, check that the battery electrolyte level is correct.
2. Using a specific gravity meter and thermometer, measure the specific gravity and temperature of the battery
electrolyte.
3. Insert the values measured in Steps 1 and 2 in the formula
below, and calculate S20.
S20=St+0.0007(t-20)
S20:Specific gravity at 20C

St:Specific gravity (measured value)at tC
t:Temperature of battery electrolyte (measured value)
Normal value:S20=1.27 - 1.29

4. Charge the battery if necessary.
Specific gravity Condition of Necessity to

of electrolyte charge charge
1.280 Fully charged
No
1.240 1/4 discharged
1.210 1/2 discharged
Yes
1.130 Fully discharged
4 - 23
.
CLEAN RADIATOR FINS, CHECK FOR DAMAGE
CLEANING
CAUTION
Dirt may fly and get into your eyes, so always wear protective glasses or
goggles.
Blow the radiator fins with compressed air, steam, or water.

Air pressure:0.98 MPa (10 kgf/cm2)
Steam pressure:0.39 MPa (4 kgf/cm2)
When using air or steam, always point the nozzle at a right angle
to the radiator when cleaning.
TESTING
Check visually that there are no dents or damage to the fins.
CLEAN INSIDE OF COOLING SYSTEM

CAUTION
Right after the engine has stopped, the cooling water is at a high temperature, so there is always the danger of burns if the hot
cooling water is drained immediately. Wait until the hot cooling water cools down sufficiently and then carry out draining.
The engine is cleaned while it is running, and the lift truck may begin to start off all of sudden. Therefore, it is extremely
dangerous to crawl under the truck. Never attempt such a reckless act so long as the engine is running.
While the engine cooling water is still at a high temperature, do not try to unscrew the radiator cap, as boiling water will likely
spurt out. Unscrew the cap only after the temperature goes down sufficiently and turn the cap slowly to release the internal
pressure.
When engine cooling water is replaced, or when the radiator or carburetor is replaced with a new one, the engine sometimes
overheats unless air is completely bled from the cooling system. Therefore, make sure that air is completely bled from the
system.
CLEAN RADIATOR
Stop the lift truck on level ground.
1. Open the drain valves at the bottom of the radiator and the
engine cylinder block to drain the water.
2. Close the drain valves, fill the radiator with fresh water (tap
water) and radiator flushing fluid through the water filler, then
run the engine at idling for approx. 15 minutes.
3. Stop the engine, open the drain valves to drain the water, then
add fresh water and run the engine at idling until clean water
comes out from the drain valves (5 - 10 minutes).
4. Stop the engine, drain all the water from the drain valves, then close the drain valves and fill the radiator with
fresh water and long life coolant.
For the right amount of cooling water, refer to "LUBRICANT LIST (PAGE 4-17)".
4 - 24
.
If air is not completely bled from the engine cooling system after cooling water is replaced, sometimes the engine
overheats. So carry out this air bleeding without fail.
Cautions when replacing engine cooling water

If water is provided in a gush from a hose, air bubbles will be contained in the water, so pour water in the radiator
tank gradually.
In order to determine if enough water has been provided in the tank after the initial pouring, idle the engine for
about 5 to 10 minutes without the radiator cap being in place to release air inside the engine, and then stop the
engine to check the water level.
Pour cooling water in the reservoir tank, too, up to the specified level.
CAUTION
Coolant is flammable, so keep it away from open flame.
NOTICE
In cold areas, add long life coolant (Non-amine type).
(For details, see "COLD WEATHER OPERATION (PAGE 3-29)".)
When not using long life coolant, add rust prevention fluid to the radiator.
Always use genuine Komatsu Forklift products for the flushing fluid, rust prevention fluid, and long life coolant.
4 - 25
.
CHANGE OIL IN DIFFERENTIAL CASE (FOR CLUTCH TYPE LIFT TRUCKS, INCLUDES
TRANSMISSION CASE)
CAUTION
Immediately after operations, the oil is at high temperature. Wait for the temperature to go down before starting this operation.
CHECK OIL LEVEL

1. Remove the oil filler plug that doubles as an oil level check plug
and check the hydraulic oil level. When oil comes up as high as
the lower line in the plug hole, then the amount of the oil is
sufficient.
If it does not, refill with additional oil.
CHANGE OIL
1. Remove the oil filler plug that doubles as an oil level check plug
and drain plug, and then drain the hydraulic oil.
2. After draining the oil, tighten the drain plug and add the
specified amount of oil through the oil filler.
3. After filling with oil, check the oil level.
NOTICE
For the gear oil, be sure to use genuine gear oil of Komatsu Forklift.
REMARKS
On clutch type lift trucks, the oil is used for both the differential case
and the transmission case. However, on the TORQFLOW
transmission lift truck, each case has its own special oil, so it is
necessary to check and change the oil in the TORQFLOW
transmission case in addition to checking and changing the oil in
the differential case.
4 - 26
.
CHANGE OIL IN TORQFLOW TRANSMISSION CASE AND CLEAN STRAINER
CHECK OIL LEVEL

1. Open the inspection window in the floor plate and check with the dipstick.
2. If the oil level is low, remove the oil filler plug and add oil.
CHANGE OIL, CLEAN STRAINER

1. Remove the drain plug, drain the oil, then tighten the plug
again.
2. Remove the mounting bolts, take out the strainer, and wash it
in flushing oil.
3. After washing, blow air from within the strainer to dry it off, and
then install it again.
If the strainer is clogged or broken, replace it with a new one.
4. Add the specified amount of oil through the oil filler port.
5. After filling with oil, check the oil level.

NOTICE
For the engine oil, be sure to use genuine engine oil of Komatsu Forklift.
4 - 27
.
CHANGE HYDRAULIC OIL

CAUTION
Immediately after operations, the oil is at high temperature. Never change the oil immediately after stopping operations.
Wait for the oil temperature to go down before changing the oil.
1. Drain the oil from the drain plug at the bottom of the tank, then
remove the cover, take out the strainer, and wash it in flushing
oil.
2. Clean the inside of the tank, then install the drain plug.
3. After washing the strainer, blow air from the inside of the
strainer to dry it completely, then install it again.
4. Replace the line filter, then install the cover.
5. Add the specified amount of hydraulic oil through the insertion
port of the breather (with dipstick), then check the oil level with
the dipstick.
6. Start the engine, then operate the cylinders (lift, tilt) to the end
of their travel 5 - 6 times to bleed the air.
NOTICE
Always use Komatsu Forklift genuine hydraulic oil.
4 - 28
.
MAINTENANCE REPLACING TIRES
REPLACING TIRES
WARNING
Check that the rim nuts are not loosened, and then loosen hub nuts.
Never loosen the rim nuts, mistaking them for the hub nuts.
When lifting the lift truck with a jack, carry out the work, often checking that the jack does not slip off, and never crawl under
the lifted truck.
The tires are filled with highly pressurized air. For this reason, a deformed or cracked rim poses a big danger. Before filling with
air, check the tires thoroughly for deformation or crack, and do not use any defective tire.
Set the air pressure of an air compressor for use at the specified value beforehand so that air of higher pressure than specified
will not be sent to the tires.
Leave the disassembly and reassembly work of the tires with professionals.
1. Stop the lift truck on flat ground in a safe area and apply the
parking brake.
2. Put blocks under the tire diagonally opposite to the tire which
is to be replaced.
3. Using a hub nut wrench, loosen hub nuts (1) to a point where
they can be turned by hand.
4. Set a jack at the jacking point (see diagram on right), then jack
up the lift truck to a point where the tire comes off the ground.
(A): Front tire jacking point (Under outer mast)
(B): Rear tire jacking point (Under counterweight)
5. Remove hub nuts (1), then remove the tire and replace it.
6. Install the replacement tire and partially tighten hub nuts (1).
7. Tighten hub nuts (1) in turn on opposite sides until there is no
play in the wheel.
8. Lower the jack to lower the lift truck to the ground, then tighten
hub nuts (1) to the specified tightening torque. (For details of
the tightening torque, see "SERVICE DATA (PAGE 4-32)".)
9. Adjust the inflation pressure of the tire to the specified

pressure. (For details of the inflation pressure, see "SERVICE
DATA (PAGE 4-32)".)
4 - 29
.
REPLACING FUSES MAINTENANCE
REPLACING FUSES
CAUTION
When replacing the fuses, always turn off the electric power (turn the starting switch to the OFF position) before starting.
Always replace the fuses with a fuse of the same capacity.
The fuses are used to protect the electrical components and wiring from burning out.
1. Turn the starting switch to the OFF position.

Open up the engine hood. (A fuse box and relay box are located close to the battery on the right side of the
chassis.)
2. Open the fuse box cover and replace the fuse inside. (To open the fuse box cover, pull it back while pressing
the side of the box lightly with your fingers, then it can be taken off.
Check the relationship between the fuses and the electrical components when replacing.
Fuse box
Fuse capacity and related electrical component

No. Capacity Color Related electrical component
(1) 15A Blue Head lamp
(2) 10A Red Position lamp
(3) 10A Red Horn, Stop lamp
(4) 10A Red Starting relay
(5) 15A Blue Back lamp
(6) 10A Red Meters
(7) - - Spare
The unmarked fuses (10A x 2, 15A x 1, 20A x 1) are spares.
Relay box
Fuse capacity and related

No. Capacity Related electrical component
(8) 60A Starting motor
(9) 40A Starting motor switch
100A (Gasoline engine
lift truck)
(10) Charger
120A (Diesel engine
lift truck)
4 - 30
.
MAINTENANCE REPLACING LAMPS
REPLACING LAMPS
1. Check that fuses are not blown and wires are not disconnected.
2. If disconnection is found, turn OFF the lamp switch and replace the lamp.
Lamp capacity
Head lamp 55W (For 12V)
Turn signal lamp 23W (For 12V)
Clearance lamp 8W (For 12V)
Number plate lamp (option) 10W (For 12V)
Back lamp 8W (For 12V)
Stop lamp 23W (For 12V)
Warning lamp 1.4W (For 12V)
Meter lighting lamp 1.4W (For 12V)
4 - 31
.
SERVICE DATA MAINTENANCE
SERVICE DATA
SERVICE DATA (GASOLINE ENGINE LIFT TRUCK)
Component Inspection item Unit FG10/15/18-20 FG15H/18H-20
Engine model - NISSAN K15 NISSAN K21
Idling speed rpm 750 - 900 750 - 900
Engine proper Max. speed rpm 2840 - 3040 2840 - 3040
MPa
Compression 1.27(13.0)/250 1.23(12.5)/250
(kgf/cm2)/rpm
11 - 13 (0.43 - 0.51) 11 - 13 (0.43 - 0.51)
Lubricating oil
(finger pressure: 98 N) (finger pressure: 98 N)
cooling Fan belt deflection mm (in)
11 - 13 (0.43 - 0.51) 11 - 13 (0.43 - 0.51)
system
(finger pressure:10 kgf) (finger pressure:10 kgf)
Injection timming deg-BTDC - -
Engine
Fuel system Injection order - - -

Injection pressure MPa(kgf/cm2) - -
Intake, Intake mm (in) 0.38 (0.015) [Warm] 0.38 (0.015) [Warm]
Valve
exhaust
clearance Exhaust mm (in) 0.38 (0.015) [Warm] 0.38 (0.015) [Warm]
system
Distributor point gap mm (in) - -
Spark plug gap mm (in) 0.8 - 0.9 (0.031 - 0.035) 0.8 - 0.9 (0.031 - 0.035)
Electric Spark plug type - FR2A-D (NGK) FR2A-D (NGK)
system deg-BTDC
Ignition timing 4/850 2/850
/rpm
Firing order - 1-3-4-2 1-3-4-2
Tire inflation Front wheels kPa (kgf/cm2) 690 (7.0) 690 (7.0)
Tires
Travel system
pressure Rear wheels kPa (kgf/cm2) 790 (8.0) 790 (8.0)

Tightening Front wheels Nm(kgfm) 157 - 245 (16 - 25) 157 - 245 (16 - 25)
Hub nuts
torque Rear wheels Nm(kgfm) 83 - 147 (8.5 - 15) 83 - 147 (8.5 - 15)
Rim mating Tightening Front wheels Nm(kgfm) 88 - 123 (9.0 - 12.5) 88 - 123 (9.0 - 12.5)
nuts torque Rear wheels Nm(kgfm) 59 - 74 (6.0 - 7.5) 59 - 74 (6.0 - 7.5)
Steering Play (At the time of a pump
mm (in) 30 - 60 (1.2 - 2.4) 30 - 60 (1.2 - 2.4)
wheel operation)
Clutch pedal Play mm (in) 0 - 4 (0 - 0.158) 0 - 4 (0 - 0.158)
Steering, braking system
Play mm (in) 0 - 4 (0 - 0.158) 0 - 4 (0 - 0.158)

Inching pedal
Interconnected travel mm (in) 35 - 41 (1.38 - 1.61) 35 - 41 (1.38 - 1.61)
Play mm (in) 0 - 4 (0 - 0.158) 0 - 4 (0 - 0.158)
Brake pedal Pedal height when pedal is
mm (in) 76 - 96 (3.0 - 3.8) 76 - 96 (3.0 - 3.8)
depressed
Parking brake operating
N (kgf) 147 - 196 (15 - 20) 147 - 196 (15 - 20)
force
Brake
Tightening torque for
Nm (kgfm) 176 - 196 (18 - 20) 176 - 196 (18 - 20)
back plate mounting bolts
1.0 ton lift truck: Min. 26 (1.02)
Loading equipment
Forks Fork thickness (at base) mm (in) 1.5 ton lifr truck: Min. 30 (1.18)
Chain Length over 17 links mm (in) Max. 275.5 (10.8) Max. 275.5 (10.8)
Hydraulic
Relief pressure MPa (kgf/cm2) 17.2 (175) 17.2 (175)
system
4 - 32
.
MAINTENANCE SERVICE DATA
Component Inspection item Unit FG20/25-16 FG20H/25H-16 FG20N/25N-16

Engine model - NISSAN K21 NISSAN K25 NISSAN K21
Idling speed rpm 750 - 900 750 - 900 750 - 900
Engine
Max. speed rpm 2840 - 3040 2720 - 2920 2840 - 3040
proper
MPa 1.23 (12.5) 1.27(13.0) 1.23 (12.5)
Compression
(kgf/cm2)/rpm /250 /250 /250
11 - 13 11 - 13 11 - 13
Lubricating (0.43 - 0.51) (0.43 - 0.51) (0.43 - 0.51)
oil [finger pressure: 98 N] [finger pressure: 98 N] [finger pressure: 98 N]
Fan belt deflection mm (in)
cooling 11 - 13 11 - 13 11 - 13
system (0.43 - 0.51) (0.43 - 0.51) (0.43 - 0.51)
[finger pressure:10 kgf] [finger pressure:10 kgf] [finger pressure:10 kgf]
Engine
Injection timming deg-BTDC - - -

Fuel system Injection order - - - -
Injection pressure MPa (kgf/cm2) - - -
Intake, Intake mm (in) 0.38 (0.015) [Warm] 0.38 (0.015) [Warm] 0.38 (0.015) [Warm]
Valve
exhaust
clearance
system Exhaust mm (in) 0.38 (0.015) [Warm] 0.38 (0.015) [Warm] 0.38 (0.015) [Warm]
Distributor point gap mm (in) - - -
0.8 - 0.9 0.8 - 0.9 0.8 - 0.9
Spark plug gap mm (in)
(0.031 - 0.035) (0.031 - 0.035) (0.031 - 0.035)
Electric
Spark plug type - FR2A-D BP4ES FR2A-D
system
deg-BTDC
Ignition timing 2/850 0/850 2/850
/rpm
Firing order - 1-3-4-2 1-3-4-2 1-3-4-2
Tire inflation Front wheels kPa (kgf/cm2) 690 (7.0) 690 (7.0) -
Tires
Travel system
pressure Rear wheels kPa (kgf/cm2) 690 (7.0) 690 (7.0) -

Tightening Front wheels Nm (kgfm) 294 - 490 (30 - 50) 294 - 490 (30 - 50) 294 - 490 (30 - 50)
Hub nuts
torque Rear wheels Nm (kgfm) 157 - 245 (16 - 25) 157 - 245 (16 - 25) 157 - 245 (16 - 25)
Rim mating Tightening Front wheels Nm (kgfm) 196 - 294 (20 - 30) -
nuts torque Rear wheels Nm (kgfm) 88 - 123 (9 - 12.5) 88 - 123 (9 - 12.5) -
Steering
Play mm (in) 30 - 60 (1.2 - 2.4) 30 - 60 (1.2 - 2.4) 30 - 60 (1.2 - 2.4)
wheel
Clutch pedal Play mm (in) 0 - 4 (0 - 0.158) 0 - 4 (0 - 0.158) -

Inching Play mm (in) 0 - 4 (0 - 0.158) 0 - 4 (0 - 0.158) 0 - 4 (0 - 0.158)
pedal Interconnected travel mm (in) 35 - 41 (1.38 - 1.61) 35 - 41 (1.38 - 1.61) 35 - 41 (1.38 - 1.61)
Play mm (in) 0 - 4 (0 - 0.158) 0 - 4 (0 - 0.158) 0 - 4 (0 - 0.158)
Brake pedal Pedal height when pedal
mm (in) 62 - 82 (2.4 - 3.2) 62 - 82 (2.4 - 3.2) 62 - 82 (2.4 - 3.2)
is depressed
Parking brake operating 147 - 196 147 - 196 147 - 196
N (kgf)
force (15 - 20)(*1) (15 - 20)(*1) (15 - 20)(*1)
Brake
Nm (kgfm) 176 - 196 (18 - 20) 176 - 196 (18 - 20) 176 - 196 (18 - 20)
Loading equipment
2 ton lift truck: Min. 32.5 (1.28)

Forks Fork thickness (at base) mm (in)
Chain Length over 17 links mm (in) 2 - 2.5 ton lift truck: Max. 330 (13.0)
Hydraulic
Relief pressure MPa (kgf/cm2) 18 (185) 18 (185) 18 (185)
system
*1: In case a lift truck is equipped with power brakes, this value is 245 - 294 N (25 - 30 kgf).
*: Use BP4ES for lift trucks of LPG specifications to prevent engine knocking and run-on.
4 - 33
.
Component Inspection item Unit FG30-16 FG30N-16 FG35A-16

Engine model - NISSAN K25 NISSAN K25 NISSAN K25
Idling speed rpm 750 - 900 750 - 900 750 - 900
Engine
Max. speed rpm 2720 - 2920 2720 - 2920 2720 - 2920
proper
MPa 1.27(13.0) 1.27(13.0) 1.27(13.0)
Compression
(kgf/cm2)/rpm /250 /250 /250
11 - 13 11 - 13 11 - 13
Lubricating (0.43 - 0.51) (0.43 - 0.51) (0.43 - 0.51)
cooling 11 - 13 11 - 13 11 - 13
system (0.43 - 0.51) (0.43 - 0.51) (0.43 - 0.51)
Engine
Injection timming deg-BTDC - - -

Fuel system Injection order - - - -
Injection pressure MPa (kgf/cm2) - - -
Intake, Intake mm (in) 0.38 (0.015) [Warm] 0.38 (0.015) [Warm] 0.38 (0.015) [Warm]
Valve
exhaust
clearance
system Exhaust mm (in) 0.38 (0.015) [Warm] 0.38 (0.015) [Warm] 0.38 (0.015) [Warm]
0.8 - 0.9 0.8 - 0.9 0.8 - 0.9
Spark plug gap mm (in)
(0.031 - 0.035) (0.031 - 0.035) (0.031 - 0.035)
Electric
Spark plug type - BP4ES BP4ES BP4ES
system
deg-BTDC
Ignition timing 0/850 0/850 0/850
/rpm
Firing order - 1-3-4-2 1-3-4-2 1-3-4-2
Tire inflation Front wheels kPa (kgf/cm2) 690 (7.0) - 850 (8.5)
Tires
Travel system
pressure Rear wheels kPa (kgf/cm2) 690 (7.0) - 890 (9.0)

Hub nuts
Rim mating Tightening Front wheels Nm (kgfm) - - -
nuts torque Rear wheels Nm (kgfm) - - -
Steering
Play mm (in) 30 - 60 (1.2 - 2.4) 30 - 60 (1.2 - 2.4) 30 - 60 (1.2 - 2.4)
wheel
Clutch pedal Play mm (in) - - -

Inching Play mm (in) 0 - 4 (0 - 0.158) 0 - 4 (0 - 0.158) 0 - 4 (0 - 0.158)
pedal Interconnected travel mm (in) 35 - 41 (1.38 - 1.61) 35 - 41 (1.38 - 1.61) 40 - 46 (1.58 - 1.81)
Play mm (in) 0 - 4 (0 - 0.158) 0 - 4 (0 - 0.158) 0 - 4 (0 - 0.158)
mm (in) 62 - 82 (2.4 - 3.2) 62 - 82 (2.4 - 3.2) 62 - 82 (2.4 - 3.2)
is depressed
N (kgf)
force (15 - 20)(*1) (15 - 20)(*1) (15 - 20)(*1)
Brake
Nm (kgfm) 176 - 196 (18 - 20) 176 - 196 (18 - 20) 245 - 294 (25 - 30)
Loading equipment
3 ton lift truck: Max. 39.5 (1.60)

3.5 ton lift truck: Max. 45 (1.80)
3 ton lift truck: Max. 550 (21.7)
Chain Length over 17 links mm (in)
3.5 ton lift truck: Max. 440 (17.3)
Hydraulic
system
*1: In case a lift truck is equipped with power brakes, this value is 245 - 294 N (25 - 30 kgf).
*: Use BP4ES for lift trucks of LPG specifications to prevent engine knocking and run-on.
4 - 34
.
SERVICE DATA (DIESEL ENGINE LIFT TRUCK)

Component Inspection item Unit FD10/15/18-20
Engine model - KOMATSU 4D92E
Idling speed rpm 750 - 800
Engine proper Max. speed rpm 2650 - 2700
MPa
Compression 2.94 (30)/250
(kgf/cm2)/rpm
Lubricating oil
10 - 15 (0.39 - 0.59) [finger pressure: 98 N]
cooling Fan belt deflection mm
10 - 15 (0.39 - 0.59) [finger pressure: 10 kgf]
system
Injection timming deg-BTDC ATDC6
Engine
Fuel system Injection order - 1-3-4-2

Injection pressure MPa (kgf/cm2) 11.8 (120)
Intake, Intake mm (in) 0.2 (0.0079) [Cool]
Valve
exhaust
clearance
system Exhaust mm (in) 0.2 (0.0079) [Cool]
Distributor point gap mm (in) -
Spark plug gap mm (in) -
Electric
system deg-BTDC
Ignition timing -
/rpm
Firing order - -
Tire inflation Front wheels kPa (kgf/cm2) 690 (7.0)
Tires
Travel system
pressure Rear wheels kPa (kgf/cm2) 780 (8.0)

Tightening Front wheels Nm (kgfm) 157 - 245 (16 - 25)
Hub nuts
torque Rear wheels Nm (kgfm) 83 - 147 (8.5 - 15)
Rim mating Tightening Front wheels Nm (kgfm) 88 - 123 (9.0 - 12.5)
nuts torque Rear wheels Nm (kgfm) 59 - 74 (6.0 - 7.5)
Steering Play (At the time of a pump
mm (in) 30 - 60 (1.2 - 2.4)
wheel operation)
Clutch pedal Play mm (in) 0 - 4 (0 - 0.158)
Play mm (in) 0 - 4 (0 - 0.158)

Inching pedal
Interconnected travel mm (in) 35 - 41 (1.38 - 1.61)
Play mm (in) 0 - 4 (0 - 0.158)
Brake pedal Pedal height when pedal is
mm (in) 76 - 96 (3.0 - 3.8)
depressed
Parking brake operating
N(kgf) 147 - 196 (15 - 20)
force
Brake
Nm(kgfm) 176 - 196 (18 - 20)
Loading equipment
Forks Fork thickness (at base) mm (in) 1.5 ton lifr truck: Min. 30 (1.18)
Chain Length over 17 links mm (in) Max. 275.5 (10.8)
Hydraulic
Relief pressure MPa (kgf/cm2) 17.2 (175)
system
4 - 35
.
FD20H/25H/30H
Component Inspection item Unit FD20/25/30-16 FD20N/25N/30N-16
/35A-16
Engine model - KOMATSU 4D94LE KOMATSU 4D98E KOMATSU 4D94LE
Idling speed rpm 785 - 835 750 - 800 750 - 800
Engine
proper Max. speed rpm 2650 - 2700 2650 - 2700 2650 - 2700
MPa
Compression 2.94 (30)/250 2.94 (30)/250 2.94 (30)/250
(kgf/cm2)/rpm
10 - 15 10 - 15 10 - 15
Lubricating (0.39 - 0.59 in) (0.39 - 0.59 in) (0.39 - 0.59 in)
cooling 10 - 15 10 - 15 10 - 15
system (0.39 - 0.59 in) (0.39 - 0.59 in) (0.39 - 0.59 in)
Engine

Injection timming deg-BTDC ATDC6 ATDC6 ATDC6
Fuel system Injection order - 1-3-4-2 1-3-4-2 1-3-4-2
Injection pressure MPa (kgf/cm2) 11.8 (120) 11.8 (120) 11.8 (120)
Intake, Intake mm (in) 0.2 (0.0079 in)[Cool] 0.2 (0.0079 in)[Cool] 0.2 (0.0079 in)[Cool]
Valve
exhaust
clearance
system Exhaust mm (in) 0.2 (0.0079 in)[Cool] 0.2 (0.0079 in)[Cool] 0.2 (0.0079 in)[Cool]
Spark plug gap mm (in) - - -
Electric
deg-BTDC
system Ignition timing - - -
/rpm
Firing order - - - -
Tire inflation Front wheels kPa (kgf/cm2) 690 (7.0) 690 (7.0) -
Tires
pressure Rear wheels
Travel system
kPa (kgf/cm2) 690 (7.0) 690 (7.0) -

Hub nuts
196 - 294 (20 - 30)
Rim mating Tightening Front wheels Nm (kgfm) -
[excluding 3 ton lift truck]
nuts torque
Rear wheels Nm (kgfm) 88 - 123 (9 - 12.5) 88 - 123 (9 - 12.5) -
Steering
Play mm (in) 30 - 60 (1.2 - 2.4) 30 - 60 (1.2 - 2.4) 30 - 60 (1.2 - 2.4)
wheel
Clutch pedal Play mm (in) 0 - 4 (0 - 0.158) 0 - 4 (0 - 0.158) -

Play mm (in) 0 - 4 (0 - 0.158) 0 - 4 (0 - 0.158) 0 - 4 (0 - 0.158)
Inching
35 - 41
pedal Interconnected travel mm (in) 35 - 41 (1.38 - 1.61) 35 - 41 (1.38 - 1.61)
(1.38 - 1.61)(*1)
Play mm (in) 0 - 4 (0 - 0.158) 0 - 4 (0 - 0.158) 0 - 4 (0 - 0.158)
mm (in) 62 - 82 (2.4 - 3.2) 62 - 82 (2.4 - 3.2) 62 - 82 (2.4 - 3.2)
is depressed
N (kgf)
force (15 - 20)(*2) (15 - 20)(*2) (15 - 20)(*2)
Brake
Nm (kgfm) 176 - 196 (18 - 20) 176 - 196 (18 - 20) 176 - 196 (18 - 20)
Loading equipment

2 - 2.5 ton lift truck: Max. 330 (13.0)
Chain Length over 17 links mm (in) 3 ton lift truck: Max. 550 (21.7)
Hydraulic
system
*1: In case of FD35A, this value is 40 - 46 mm (1.6 - 1.8 in).

*2: In case of FD35A or any other lift truck equipped with power brakes, this value is 245 - 294 N (25 - 30 kgf).
4 - 36
.
TORQUE LIST
For unspecified bolts and nuts, use the torques specified in this list.
Select a proper torque corresponding to the width across flats (b)
of bolts and nuts.
When replacing bolts and nuts, always use genuine Komatsu
Forklift parts the same size as the previous ones.
Thread diameter Width across Tightening torque

of bolt (mm) flat (mm)
(a) (b) Nm kgfm lbft
6 10 13.2 1.4 1.35 0.15 9.73 1.03
8 13 31.4 2.9 3.2 0.3 23.2 2.1
10 17 65.7 6.8 6.7 0.7 48.5 5.0
12 19 112 9.8 11.5 1.0 82.6 7.2
14 22 177 19 18.0 2.0 131 14
16 24 279 29 28.5 3 206 21
18 27 383 39 39 3 282 29
20 30 549 58 56 6 405 43
22 32 745 78 76 8 549 58
24 36 927 98 94.5 10 684 72
27 41 1320 140 135 15 973 100
30 46 1720 190 175 20 1270 140
33 50 2210 240 225 25 1630 180
36 55 2750 290 280 30 2030 210
39 60 3280 340 335 35 2420 250
4 - 37
.
.
TECHNICAL DATA
5-1
.
TECHNICAL DATA TECHNICAL DATA
TECHNICAL DATA
5-2
.
AX50 (1.0 ton) Series

1.2 Model Manufacturer's Designation FG10T-20 FG10C-20 FD10T-20 FD10C-20
Electric, Diesel, Gasoline,
1.3 Power Type Gasoline Diesel
LPG
Characteristics
1.4 Operation Type Sitting Sitting

1.5 Rated Capacity Rated Capacity kg 1000 1000
1.6 Load Center Rated Load Center mm 500 500
Capacity@600mm Load
1.6.1 Alternative Capacity kg 910 910
Center
Front Axle Center to
1.8 Load Distance x mm 400 400
Fork Face
1.9 Wheelbase y mm 1400 1400
2.1 Service Weight kg 2080 2120 2180 2220
2.2 Front kg 2725 2735 2760 2765
Weight
Loaded
2.2.1 Rear kg 355 360 420 430
Axle Loading
2.3 Front kg 1065 1075 1095 1105
Unloaded
2.3.1 Rear kg 1015 1020 1085 1090
3.1 Tyre Type Pneumatic Pneumatic
3.2 Front 6.50-10-10PR(I) 6.50-10-10PR(I)
Tyre Size
Tyres
3.3 Rear 5.00- 8- 8PR(I) 5.00- 8- 8PR(I)

3.5 Number of Wheel Front/Rear (x=driven) 2*/2 2*/2
3.6 Tread, Front b4 mm 890 890
3.7 Tread, Rear b3 mm 895 895
4.1 Tilting Angle / Forward/Backward degree 6/10 6/10
4.2 Mast Height, Lowered h1 2-stage Mast mm 1995 1995
2-stage Std. Mast,
4.3 Std. Free Lift h2 mm 135 135
from Ground
2-stage Std. Mast,
4.4 Std. Lift Height h3 mm 3000 3000
from Ground
4.5 Mast Height, Extended h4 2-stage Std. Mast mm 3955 3955
4.7 Height, Overhead Guard h6 mm 2030 2030

Dimensions
4.19 Length, with Std. Forks L1 mm 2965 2965
4.20 Length, to Fork Face L2 mm 2195 2195

4.21 Width, at Tyre b1 Single mm 1070 1070
4.22 Forks Thickness x Width x Length mm 31x100x770 31x100x770
4.23 Fork Carriage Class ISO 2328, Type A/B/no Class 2 Class 2
4.24 Width, Fork Carriage b2 mm 970 970
4.31 m1 Under Mast mm 120 120
Ground Clearance
4.32 m2 at Center of Wheelbase mm 130 130
4.33 with L1000 x W1200 pallet mm 3315 3315
Right Angle Stacking Aisle
4.35 Turning Radius Wa mm 1915 1915
Loaded, 1st/2nd km/h 19.0 9.0/19.0 19.0 8.5/19.0
5.1 Travel Speed (FWD)
Unloaded, 1st/2nd km/h 19.0 9.0/19.0 19.5 8.5/19.5
Loaded mm/s 580 620
5.2 Lifting Speed
Unloaded mm/s 640 670
Loaded mm/s 500 500
Performance
5.3 Lowering Speed

5.6 Max. Drawbar Pull Loaded KN 10 11 13 14
5.8 Max. Gradeability Loaded % 34 38 49 41
5.10 Service Brake Operation/Control Foot/Hydraulic Foot/Hydraulic
5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical
5.12 Steering Type FHPS FHPS
Voltage/ Capacity at
6.4 Battery V/ah 12/33 12/64
5-hour rating
7.1 Maker Model NISSAN K15 Komatsu 4D92E
I.C Engine
7.2 Rated Output, SAE gross KW 27@2500 35@2450

7.3 Rated RPM min-1 2500 2450
7.3.1 Max. Torque, SAE gross Nm@min-1 113@1600 142@1800
No. of Cylinder/
7.4 cm3 4-1486 4-2659
Displacement
7.6 Fuel Tank Capacity Ltr 40 40
Others
Relief Pressure for

8.2 bar 172 172
Attachment
8.7 Transmission TORQFLOW Manual TORQFLOW Manual
5-3
.

Manufacturer's
1.2 Model FG15T-20 FG15C-20 FD15T-20 FD15C-20 FG15HT-20 FG15HC-20
Designation
1.3 Power Type Gasoline Diesel Gasoline
LPG
Characteristics
1.4 Operation Type Sitting Sitting Sitting

1.5 Rated Capacity Rated Capacity kg 1500 1500 1500
1.6 Load Center Rated Load Center mm 500 500 500
Capacity@600mm Load
1.6.1 Alternative Capacity kg 1360 1360 1360
Center
1.8 Load Distance x mm 405 405 405
Fork Face
1.9 Wheelbase y mm 1400 1400 1400
2.1 Service Weight kg 2450 2490 2550 2590 2450 2490
2.2 Front kg 3500 3510 3530 3540 3500 3510
Weight
Loaded
2.2.1 Rear kg 450 455 520 525 450 455
Axle Loading
2.3 Front kg 1005 1015 1035 1045 1005 1015
Unloaded
2.3.1 Rear kg 1445 1450 1515 1520 1445 1450
3.1 Tyre Type Pneumatic Pneumatic Pneumatic
3.2 Front 6.50-10-10PR(I) 6.50-10-10PR(I) 6.50-10-10PR(I)
Tyre Size
Tyres
3.3 Rear 5.00- 8- 8PR(I) 5.00- 8- 8PR(I) 5.00- 8- 8PR(I)

3.5 Number of Wheel Front/Rear (x=driven) 2*/2 2*/2 2*/2
3.6 Tread, Front b4 mm 890 890 890
3.7 Tread, Rear b3 mm 895 895 895
4.1 Tilting Angle / Forward/Backward degree 6/10 6/10 6/10
4.2 Mast Height, Lowered h1 2-stage Mast mm 1995 1995 1995
2-stage Std. Mast,
4.3 Std. Free Lift h2 mm 140 140 140
from Ground
2-stage Std. Mast,
4.4 Std. Lift Height h3 mm 3000 3000 3000
from Ground
4.5 Mast Height, Extended h4 2-stage Std. Mast mm 3955 3955 3955
4.7 Height, Overhead Guard h6 mm 2030 2030 2030
4.19 Length, with Std. Forks L1 mm 3160 3160 3160

Dimensions
4.20 Length, to Fork Face L2 mm 2240 2240 2240

4.21 Width, at Tyre b1 Single mm 1070 1070 1070
Thickness x Width x
4.22 Forks mm 35x100x920 35x100x920 35x100x920
Length
4.23 Fork Carriage Class ISO 2328, Type A/B/no Class 2 Class 2 Class 2
4.24 Width, Fork Carriage b2 mm 970 970 970
4.31 m1 Under Mast mm 120 120 120
Ground Clearance
4.32 m2 at Center of Wheelbase mm 130 130 130
4.33 with L1000 x W1200 pallet mm 3360 3360 3360
4.35 Turning Radius Wa mm 1955 1955 1955
Loaded, 1st/2nd km/h 18.5 8.5/18.5 18.5 8.5/19.0 18.5 8.5/18.5
Unloaded, 1st/2nd km/h 19.0 9.0/19.0 19.0 8.5/19.5 19.0 9.0/19.0
Loaded mm/s 570 620 590
5.2 Lifting Speed
Unloaded mm/s 640 670 640
Loaded mm/s 500 500 500
Performance
5.3 Lowering Speed

5.6 Max. Drawbar Pull Loaded KN 10 11 13 14 15 14
5.8 Max. Gradeability Loaded % 26 27 33 31 37 35
5.10 Service Brake Operation/Control Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical Hand/Mechanical
5.12 Steering Type FHPS FHPS FHPS
6.4 Battery V/ah 12/33 12/64 12/33
5-hour rating
7.1 Maker Model NISSAN K15 Komatsu 4D92E NISSAN K21
I.C Engine
7.2 Rated Output, SAE gross KW 27@2500 35@2450 35@2450

7.3 Rated RPM min-1 2500 2450 2450
7.3.1 Max. Torque, SAE gross Nm@min-1 113@1600 142@1800 152@1600
No. of Cylinder/
7.4 cm3 4-1486 4-2659 4-2065
Displacement
7.6 Fuel Tank Capacity Ltr 40 40 40
Others
Relief Pressure for

8.2 bar 172 172 172
Attachment
8.7 Transmission TORQFLOW Manual TORQFLOW Manual TORQFLOW Manual
5-4
.

Manufacturer's
1.2 Model FG18T-20 FG18C-20 FD18T-20 FD18C-20 FG18HT-20 FG18HC-20
Designation
1.3 Power Type Gasoline Diesel Gasoline
LPG
Characteristics

Capacity@600mm Load
Center
Fork Face
1.9 Wheelbase y mm 1400 1400 1400
2.2 Front kg 3870 3880 3900 3910 3870 3880
Weight
Loaded
2.2.1 Rear kg 525 530 595 600 525 530
Axle Loading
2.3 Front kg 960 970 990 1000 960 970
Unloaded
2.3.1 Rear kg 1685 1690 1755 1760 1685 1690
3.2 Front 6.50-10-10PR(I) 6.50-10-10PR(I) 6.50-10-10PR(I)
Tyre Size
Tyres
3.3 Rear 5.00- 8- 8PR(I) 5.00- 8- 8PR(I) 5.00- 8- 8PR(I)

3.6 Tread, Front b4 mm 890 890 890
3.7 Tread, Rear b3 mm 895 895 895
2-stage Std. Mast,
4.3 Std. Free Lift h2 mm 140 140 140
from Ground
2-stage Std. Mast,
from Ground

Dimensions

Thickness x Width x
4.22 Forks mm 35x100x920 35x100x920 35x100x920
Length
4.31 m1 Under Mast mm 120 120 120
Ground Clearance
Loaded, 1st/2nd km/h 18.5 8.5/18.5 18.5 8.5/18.5 18.5 8.5/18.5
Loaded mm/s 570 620 590
5.2 Lifting Speed
Loaded mm/s 500 500 500
Performance
5.3 Lowering Speed

6.4 Battery V/ah 12/33 12/64 12/33
5-hour rating
7.1 Maker Model NISSAN K15 Komatsu 4D92E NISSAN K21
I.C Engine

7.3 Rated RPM min-1 2500 2450 2450
No. of Cylinder/
7.4 cm3 4-1486 4-2659 4-2065
Displacement
Others
Relief Pressure for

8.2 bar 172 172 172
Attachment
5-5
.
BX50 (2.0 ton) Series

Manufacturer's
1.2 Model FG20T-16 FG20C-16 FD20T-16 FD20C-16 FG20HT-16 FD20HT-16 FD20HC-16
Designation
1.3 Power Type Gasoline Diesel Gasoline Diesel
LPG
Characteristics
1.4 Operation Type Sitting Sitting Sitting Sitting

1.5 Rated Capacity Rated Capacity kg 2000 2000 2000 2000
1.6 Load Center Rated Load Center mm 500 500 500 500
Capacity@600mm Load
1.6.1 Alternative Capacity kg 1810 1810 1810 1810
Center
1.8 Load Distance x mm 460 460 460 460
Fork Face
1.9 Wheelbase y mm 1650 1650 1650 1650
2.1 Service Weight kg 3220 3255 3310 3355 3220 3310 3355
2.2 Front kg 4670 4680 4700 4720 4670 4700 4720
Weight
Loaded
2.2.1 Rear kg 550 550 610 610 550 610 610
Axle Loading
2.3 Front kg 1480 1480 1510 1520 1480 1510 1520
Unloaded
2.3.1 Rear kg 1740 1750 1800 1810 1740 1800 1810
3.1 Tyre Type Pneumatic Pneumatic Pneumatic Pneumatic
3.2 Front 7.00-12-12PR(I) 7.00-12-12PR(I) 7.00-12-12PR(I) 7.00-12-12PR(I)
Tyre Size
Tyres
3.3 Rear 6.00-09-10PR(I) 6.00-09-10PR(I) 6.00-09-10PR(I) 6.00-09-10PR(I)

3.5 Number of Wheel Front/Rear (x=driven) 2*/2 2*/2 2*/2 2*/2
3.6 Tread, Front b4 mm 965 965 965 965
3.7 Tread, Rear b3 mm 960 960 960 960
4.1 Tilting Angle / Forward/Backward degree 6/12 6/12 6/12 6/12
4.2 Mast Height, Lowered h1 2-stage Mast mm 1995 1995 1995 1995
2-stage Std. Mast,
4.3 Std. Free Lift h2 mm 150 150 150 150
from Ground
2-stage Std. Mast,
4.4 Std. Lift Height h3 mm 3000 3000 3000 3000
from Ground
4.5 Mast Height, Extended h4 2-stage Std. Mast mm 4050 4050 4050 4050
4.7 Height, Overhead Guard h6 mm 2070 2070 2070 2070
4.19 Length, with Std. Forks L1 mm 3450 3450 3450 3450

Dimensions
4.20 Length, to Fork Face L2 mm 2530 2530 2530 2530

4.21 Width, at Tyre b1 Single mm 1150 1150 1150 1150
Thickness x Width x
4.22 Forks mm 36x122x920 36x122x920 36x122x920 36x122x920
Length
4.23 Fork Carriage Class ISO 2328, Type A/B/no Class 2 Class 2 Class 2 Class 2
4.24 Width, Fork Carriage b2 mm 1020 1020 1020 1020
4.31 m1 Under Mast mm 115 115 115 115
Ground Clearance
4.32 m2 at Center of Wheelbase mm 160 160 160 160
4.33 with L1000 x W1200 pallet mm 3650 3650 3650 3650
4.35 Turning Radius Wa mm 2190 2190 2190 2190
Loaded, 1st/2nd km/h 18.5 8.5/18.5 18.5 8.5/18.5 19.0 18.5 8.0/18.5
Unloaded, 1st/2nd km/h 19.0 9.0/19.0 19.0 8.5/19.0 19.5 19.0 8.5/19.0
Loaded mm/s 545 630 620 660
5.2 Lifting Speed
Unloaded mm/s 600 685 670 710
Loaded mm/s 450 450 450 450
Performance
5.3 Lowering Speed

Unloaded mm/s 500 500 500 500
5.6 Max. Drawbar Pull Loaded KN 14 14 18 17 19 22 21
5.8 Max. Gradeability Loaded % 28 27 36 34 38 45 44
5.10 Service Brake Operation/Control Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical Hand/Mechanical Hand/Mechanical
5.12 Steering Type FHPS FHPS FHPS FHPS
6.4 Battery V/ah 12/33 12/64 12/33 12/64
5-hour rating
7.1 Maker Model NISSAN K21 Komatsu 4D94LE NISSAN K25 Komatsu 4D98E
I.C Engine
7.2 Rated Output, SAE gross KW 35@2450 46@2450 43@2400 53@2400

7.3 Rated RPM min-1 2450 2450 2400 2400
7.3.1 Max. Torque, SAE gross Nm@min-1 152@1600 186@1800 186@1600 216@1700
No. of Cylinder/
7.4 cm3 4-2065 4-3052 4-2488 4-3318
Displacement
7.6 Fuel Tank Capacity Ltr 58 58 58 58
Others
Relief Pressure for

8.2 bar 181 181 181 181
Attachment
8.7 Transmission TORQFLOW Manual TORQFLOW Manual TORQFLOW TORQFLOW Manual
5-6
.

Manufacturer's
1.2 Model FG25T-16 FG25C-16 FD25T-16 FD25C-16 FG25HT-16 FD25HT-16 FD25HC-16
Designation
1.3 Power Type Gasoline Diesel Gasoline Diesel
LPG
Characteristics
1.4 Operation Type Sitting Sitting Sitting Sitting

1.5 Rated Capacity Rated Capacity kg 2500 2500 2500 2500
1.6 Load Center Rated Load Center mm 500 500 500 500
Capacity@600mm Load
1.6.1 Alternative Capacity kg 2270 2270 2270 2270
Center
1.8 Load Distance x mm 465 465 465 465
Fork Face
1.9 Wheelbase y mm 1650 1650 1650 1650
2.1 Service Weight kg 3590 3625 3680 3725 3590 3680 3725
2.2 Front kg 5420 5430 5460 5470 5420 5460 5470
Weight
Loaded
2.2.1 Rear kg 670 670 720 730 670 720 730
Axle Loading
2.3 Front kg 1430 1430 1460 1470 1430 1460 1470
Unloaded
2.3.1 Rear kg 2160 2170 2220 2230 2160 2220 2230
3.1 Tyre Type Pneumatic Pneumatic Pneumatic Pneumatic
3.2 Front 7.00-12-12PR(I) 7.00-12-12PR(I) 7.00-12-12PR(I) 7.00-12-12PR(I)
Tyre Size
Tyres
3.3 Rear 6.00-09-10PR(I) 6.00-09-10PR(I) 6.00-09-10PR(I) 6.00-09-10PR(I)

3.5 Number of Wheel Front/Rear (x=driven) 2*/2 2*/2 2*/2 2*/2
3.6 Tread, Front b4 mm 965 965 965 965
3.7 Tread, Rear b3 mm 960 960 960 960
4.1 Tilting Angle / Forward/Backward degree 6/12 6/12 6/12 6/12
4.2 Mast Height, Lowered h1 2-stage Mast mm 1995 1995 1995 1995
2-stage Std. Mast,
4.3 Std. Free Lift h2 mm 155 155 155 155
from Ground
2-stage Std. Mast,
4.4 Std. Lift Height h3 mm 3000 3000 3000 3000
from Ground
4.5 Mast Height, Extended h4 2-stage Std. Mast mm 4050 4050 4050 4050
4.7 Height, Overhead Guard h6 mm 2070 2070 2070 2070
4.19 Length, with Std. Forks L1 mm 3655 3655 3655 3655

Dimensions
4.20 Length, to Fork Face L2 mm 2585 2585 2585 2585

4.21 Width, at Tyre b1 Single mm 1150 1150 1150 1150
Thickness x Width x
4.22 Forks mm 40x122x1070 40x122x1070 40x122x1070 40x122x1070
Length
4.23 Fork Carriage Class ISO 2328, Type A/B/no Class 2 Class 2 Class 2 Class 2
4.24 Width, Fork Carriage b2 mm 1020 1020 1020 1020
4.31 m1 Under Mast mm 115 115 115 115
Ground Clearance
4.32 m2 at Center of Wheelbase mm 160 160 160 160
4.35 Turning Radius Wa mm 2240 2240 2240 2240
Loaded, 1st/2nd km/h 18.5 8.5/18.5 18.5 8.5/18.5 19.0 18.5 8.0/18.5
Unloaded, 1st/2nd km/h 19.0 9.0/19.0 19.0 8.5/19.0 19.5 19.0 8.5/19.0
Loaded mm/s 545 630 620 660
5.2 Lifting Speed
Unloaded mm/s 600 685 670 710
Loaded mm/s 450 450 450 450
Performance
5.3 Lowering Speed

Unloaded mm/s 500 500 500 500
5.6 Max. Drawbar Pull Loaded KN 14 14 18 17 19 22 21
5.8 Max. Gradeability Loaded % 23 22 31 29 32 37 37
5.10 Service Brake Operation/Control Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical Hand/Mechanical Hand/Mechanical
5.12 Steering Type FHPS FHPS FHPS FHPS
6.4 Battery V/ah 12/33 12/64 12/33 12/64
5-hour rating
7.1 Maker Model NISSAN K21 Komatsu 4D94LE NISSAN K25 Komatsu 4D98E
I.C Engine
7.2 Rated Output, SAE gross KW 35@2450 46@2450 43@2400 53@2400

7.3 Rated RPM min-1 2450 2450 2400 2400
7.3.1 Max. Torque, SAE gross Nm@min-1 152@1600 186@1800 186@1600 216@1700
No. of Cylinder/
7.4 cm3 4-2065 4-3052 4-2488 4-3318
Displacement
7.6 Fuel Tank Capacity Ltr 58 58 58 58
Others
Relief Pressure for

8.2 bar 181 181 181 181
Attachment
8.7 Transmission TORQFLOW Manual TORQFLOW Manual TORQFLOW TORQFLOW Manual
5-7
.

Manufacturer's
1.2 Model FG30T-16 FG30C-16 FD30T-16 FD30C-16 FD30HT-16 FD30HC-16
Designation
1.3 Power Type Gasoline Diesel Diesel
LPG
Characteristics

Capacity@600mm Load
Center
Fork Face
1.9 Wheelbase y mm 1700 1700 1700
2.2 Front kg 6390 6400 6430 6440 6430 6440
Weight
Loaded
2.2.1 Rear kg 820 830 880 880 880 880
Axle Loading
2.3 Front kg 1600 1610 1640 1650 1640 1650
Unloaded
2.3.1 Rear kg 2610 2620 2670 2670 2670 2670
3.2 Front 28x9-15-12PR(I) 28x9-15-12PR(I) 28x9-15-12PR(I)
Tyre Size
Tyres
3.3 Rear 6.50-10-10PR(I) 6.50-10-10PR(I) 6.50-10-10PR(I)

3.6 Tread, Front b4 mm 1005 1005 1005
3.7 Tread, Rear b3 mm 965 965 965
2-stage Std. Mast,
4.3 Std. Free Lift h2 mm 160 160 160
from Ground
2-stage Std. Mast,
from Ground

Dimensions

Thickness x Width x
4.22 Forks mm 44x122x1070 44x122x1070 44x122x1070
Length
4.31 m1 Under Mast mm 135 135 135
Ground Clearance
Loaded, 1st/2nd km/h 18.5 8.5/18.5 19.0 8.5/18.5 18.5 8.0/18.5
Loaded mm/s 515 520 550
5.2 Lifting Speed
Loaded mm/s 400 420 420
Performance
5.3 Lowering Speed

6.4 Battery V/ah 12/33 12/64 12/64
5-hour rating
7.1 Maker Model NISSAN K25 Komatsu 4D94LE Komatsu 4D98E
I.C Engine

7.3 Rated RPM min-1 2400 2450 2400
No. of Cylinder/
7.4 cm3 4-2488 4-3052 4-3318
Displacement
Others
Relief Pressure for

8.2 bar 181 181 181
Attachment
5-8
.

1.2 Model Manufacturer's Designation FG35A-16 FD35A-16
1.3 Power Type Gasoline Diesel
LPG
Characteristics
1.4 Operation Type Sitting Sitting

1.5 Rated Capacity Rated Capacity kg 3500 3500
1.6 Load Center Rated Load Center mm 500 500
Capacity@600mm Load
1.6.1 Alternative Capacity kg 3180 3180
Center
1.8 Load Distance x mm 505 505
Fork Face
1.9 Wheelbase y mm 1700 1700
2.1 Service Weight kg 4910 5010
2.2 Front kg 7440 7480
Weight
Loaded
2.2.1 Rear kg 970 1030
Axle Loading
2.3 Front kg 1820 1860
Unloaded
2.3.1 Rear kg 3090 3150
3.1 Tyre Type Pneumatic Pneumatic
3.2 Front 250-15-16PR(I) 250-15-16PR(I)
Tyre Size
Tyres
3.3 Rear 6.50x10-12PR(I) 6.50x10-12PR(I)

3.5 Number of Wheel Front/Rear (x=driven) 2*/2 2*/2
3.6 Tread, Front b4 mm 1060 1060
3.7 Tread, Rear b3 mm 965 965
4.1 Tilting Angle / Forward/Backward degree 6/12 6/12
4.2 Mast Height, Lowered h1 2-stage Mast mm 2100 2100
2-stage Std. Mast,
4.3 Std. Free Lift h2 mm 145 145
from Ground
2-stage Std. Mast,
4.4 Std. Lift Height h3 mm 3000 3000
from Ground
4.5 Mast Height, Extended h4 2-stage Std. Mast mm 4280 4280
4.7 Height, Overhead Guard h6 mm 2105 2105

Dimensions
4.19 Length, with Std. Forks L1 mm 3865 3865
4.20 Length, to Fork Face L2 mm 2795 2795

4.21 Width, at Tyre b1 Single mm 1290 1290
4.22 Forks Thickness x Width x Length mm 50x150x1070 50x150x1070
4.23 Fork Carriage Class ISO 2328, Type A/B/no Class 3 Class 3
4.24 Width, Fork Carriage b2 mm 1060 1060
4.31 m1 Under Mast mm 135 135
Ground Clearance
4.32 m2 at Center of Wheelbase mm 185 185
4.35 Turning Radius Wa mm 2480 2480
Loaded, 1st/2nd km/h 18.0 18.0
Unloaded, 1st/2nd km/h 19.0 19.0
Loaded mm/s 410 450
5.2 Lifting Speed
Loaded mm/s 400 420
Performance
5.3 Lowering Speed

5.6 Max. Drawbar Pull Loaded KN 16 20
5.8 Max. Gradeability Loaded % 20 26
5.10 Service Brake Operation/Control Foot/Hydraulic Foot/Hydraulic
5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical
5.12 Steering Type FHPS FHPS
6.4 Battery V/ah 12/33 12/64
5-hour rating
7.1 Maker Model NISSAN K25 Komatsu 4D98E
I.C Engine
7.2 Rated Output, SAE gross KW 43@2400 53@2400

7.3 Rated RPM min-1 2400 2400
7.3.1 Max. Torque, SAE gross Nm@min-1 186@1600 216@1700
No. of Cylinder/
7.4 cm3 4-2488 4-3318
Displacement
7.6 Fuel Tank Capacity Ltr 58 58
Others
Relief Pressure for

8.2 bar 181 181
Attachment
8.7 Transmission TORQFLOW TORQFLOW
5-9
.
BX50 109 Series

Manufacturer's
1.2 Model FG20NT-16 FD20NT-16 FG25NT-16 FD25NT-16 FG30NT-16 FD30NT-16
Designation
1.3 Power Type Gasoline Diesel Gasoline Diesel Gasoline Diesel
LPG
Characteristics
1.4 Operation Type Sitting Sitting Sitting Sitting Sitting Sitting

1.5 Rated Capacity Rated Capacity kg 2000 2000 2500 2500 3000 3000
1.6 Load Center Rated Load Center mm 500 500 500 500 500 500
Capacity@600mm Load
1.6.1 Alternative Capacity kg 1810 1810 2270 2270 2720 2720
Center
1.8 Load Distance x mm 430 430 435 435 440 440
Fork Face
1.9 Wheelbase y mm 1400 1400 1400 1400 1450 1450
2.2 Front kg 4600 4630 5350 5380 6250 6240
Weight
Loaded
2.2.1 Rear kg 630 700 780 850 820 930
Axle Loading
2.3 Front kg 1250 1280 1140 1170 1260 1250
Unloaded
2.3.1 Rear kg 1980 2050 2490 2560 2810 2920
3.1 Tyre Type Pneumatic Pneumatic Pneumatic Pneumatic Pneumatic Pneumatic
22 1/4 x7 22 1/4 x7 22 1/4 x7 22 1/4 x7 22 1/4 x7 22 1/4 x7
3.2 Front
1/2-15/5.50 1/2-15/5.50 1/2-15/5.50 1/2-15/5.50 1/2-15/5.50 1/2-15/5.50
Tyre Size
Tyres
17 3/4 x6 17 3/4 x6 17 3/4 x6 17 3/4 x6 17 3/4 x6 17 3/4 x6

3.3 Rear
1/2 -10/5.00 1/2 -10/5.00 1/2 -10/5.00 1/2 -10/5.00 1/2 -10/5.00 1/2 -10/5.00
3.5 Number of Wheel Front/Rear (x=driven) 2*/2 2*/2 2*/2 2*/2 2*/2 2*/2
3.6 Tread, Front b4 mm 900 900 900 900 900 900
3.7 Tread, Rear b3 mm 885 885 885 885 885 885
4.1 Tilting Angle / Forward/Backward degree 6/10 6/10 6/10 6/10 6/10 6/10
4.2 Mast Height, Lowered h1 2-stage Mast mm 1995 1995 1995 1995 2070 2070
2-stage Std. Mast,
4.3 Std. Free Lift h2 mm 150 150 155 155 160 160
from Ground
2-stage Std. Mast,
4.4 Std. Lift Height h3 mm 3000 3000 3000 3000 3000 3000
from Ground
4.5 Mast Height, Extended h4 2-stage Std. Mast mm 4050 4050 4050 4050 4275 4275
4.7 Height, Overhead Guard h6 mm 2025 2025 2025 2025 2025 2025
4.19 Length, with Std. Forks L1 mm 3260 3260 3475 3475 3535 3535
Dimensions
4.20 Length, to Fork Face L2 mm 2340 2340 2405 2405 2465 2465
4.21 Width, at Tyre b1 Single mm 1090 1090 1090 1090 1090 1090
Thickness x Width x
4.22 Forks mm 36x122x920 36x122x920 40x122x1070 40x122x1070 44x122x1070 44x122x1070
Length
4.23 Fork Carriage Class ISO 2328, Type A/B/no Class 2 Class 2 Class 2 Class 2 Class 3 Class 3
4.24 Width, Fork Carriage b2 mm 960 960 960 960 940 940
4.31 m1 Under Mast mm 105 105 105 105 105 105
Ground Clearance
4.32 m2 at Center of Wheelbase mm 115 115 115 115 115 115
4.33 with L1000 x W1200 pallet mm 3410 3410 3555 3555 3620 3620
4.34 with L1200 x W800 pallet mm 3610 3610 3685 3685 3750 3750
4.35 Turning Radius Wa mm 1980 1980 2050 2050 2110 2110
Loaded, 1st/2nd km/h 17.0 17.0 16.5 16.5 16.0 16.0
Unloaded, 1st/2nd km/h 16.5 16.5 16.5 16.5 16.0 16.0
Loaded mm/s 545 630 545 630 515 520
5.2 Lifting Speed
Unloaded mm/s 600 685 600 685 550 555
Loaded mm/s 450 450 450 450 420 420
Performance
5.3 Lowering Speed

Unloaded mm/s 500 500 500 500 500 500
5.10 Service Brake Operation/Control Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
Hand/ Hand/ Hand/ Hand/ Hand/ Hand/
5.11 Parking Brake Operation/Control
Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical
5.12 Steering Type FHPS FHPS FHPS FHPS FHPS FHPS
6.4 Battery V/ah 12/33 12/64 12/33 12/64 12/33 12/64
5-hour rating
Komatsu Komatsu Komatsu
7.1 Maker Model NISSAN K21 NISSAN K21 NISSAN K25
4D94LE 4D94LE 4D94LE
I.C Engine
7.2 Rated Output, SAE gross KW 35@2450 46@2450 35@2450 46@2450 43@2400 46@2450
7.3 Rated RPM min-1 2450 2450 2450 2450 2400 2450
7.3.1 Max. Torque, SAE gross Nm@min-1 152@1600 186@1800 152@1600 186@1800 186@1600 186@1800
No. of Cylinder/
7.4 cm3 4-2065 4-3052 4-2065 4-3052 4-2488 4-3052
Displacement
7.6 Fuel Tank Capacity Ltr 40 40 40 40 40 40
Others
Relief Pressure for

8.2 bar 181 181 181 181 181 181
Attachment
8.7 Transmission TORQFLOW TORQFLOW TORQFLOW TORQFLOW TORQFLOW TORQFLOW
5 - 10
.
INDEX
INDEX
<A> INTRODUCTION OF OPTIONAL

ACTIONS IN ENGINE OVERHEATING 3- 31 EQUIPMENT 2- 36
ADJUSTING POSITION OF STEERING
WHEEL 3- 15 <K>
APPLICABLE LIFT TRUCK SERIAL NO. 1- 7 KOMATSU FORKLIFT GENUINE PARTS 1- 5
APPLICABLE LIFT TRUCK SERIAL NO. <L>
LOCATION 1- 7 LOAD HANDLING OPERATION 3- 26
LOADING OPERATIONS 2- 15
<C> LOCATION OF PLATES 1- 7
CHECK AFTER OPERATION 4- 13 LONG-TERM STORAGE 3- 32
CHECK BEFORE OPERATION 4- 2 AFTER STORAGE 3- 32
CHECK AFTER STARTING (WITH BEFORE STORAGE 3- 32
STARTING SWITCH ON) 4- 8 DURING STORAGE 3- 32
CHECK BEFORE OPERATION (WITH LUBRICANT LIST 4- 16
KEY SWITCH OFF) 4- 2 OIL AND GREASING CHART
CHECK OF WORK EQUIPMENT (OIL, GREASE LOCATIONS AND
OPERATION 4- 12 INSPECTION AND MAINTENANCE
CHECK WHILE ADVANCING INTERVALS) 4- 16
SLOWLY 4- 12 LUBRICANT LIST 4- 17
COLD WEATHER OPERATION 3- 29
PRECAUTIONS AFTER <M>
COMPLETION OF OPERATIONS 3- 30 MAINTENANCE 4- 19
PREPARATIONS FOR LOW CHANGE HYDRAULIC OIL 4- 28
TEMPERATURE 3- 29 CHANGE OIL IN DIFFERENTIAL
COMBINATION SWITCH OPERATION 3- 28 CASE (FOR CLUTCH TYPE LIFT
TRUCKS, INCLUDES
<D> TRANSMISSION CASE) 4- 26
DIRECTION OF TRUCK 1- 4 CHANGE OIL IN TORQFLOW
TRANSMISSION CASE AND CLEAN
<E> STRAINER 4- 27
EMBOSSED SERIAL NO. LOCATION 1- 8 CHECK BATTERY ELECTROLYTE
EXPLANATION OF COMPONENTS 3- 5 SPECIFIC GRAVITY 4- 23
CLEAN INSIDE OF COOLING
<F> SYSTEM 4- 24
FIRST MONTH SERVICE (OR INITIAL CLEAN RADIATOR FINS, CHECK
200 HOURS SERVICE) FOR NEW LIFT FOR DAMAGE 4- 24
TRUCK 1- 6 CLEAN, REPLACE AIR CLEANER
FOREWORD 1- 2 ELEMENT 4- 22
FORK SPREAD ADJUSTMENT 3- 25 MAINTENANCE OF ENGINE 4- 19
METER PANEL 3- 5
<G> MOUNTING/DISMOUNTING 3- 13
GENERAL VIEW 3- 2
GENERAL VIEW OF LIFT TRUCK 3- 2 <O>
OPERATION 3- 13
<I> OUTLINE OF SERVICE 4- 14
INSTRUMENTS AND CONTROLS 3- 3
6-1
.
INDEX
<P>
PERIODIC REPLACEMENT OF SAFETY
CRITICAL PARTS 4- 18
<R>
REMOVING AND INSTALLATION OF
ATTACHMENTS 3- 10
REPLACING FUSES 4- 30
REPLACING LAMPS 4- 31
REPLACING TIRES 4- 29
<S>
SAFE TRAVEL 2- 5
SAFETY IN PERIODIC MAINTENANCE 2- 20
SAFETY INFORMATION 1- 3
SAFETY MANAGEMENT 2- 2
SEAT POSITION ADJUSTMENT 3- 13
SERVICE DATA 4- 32
SERVICE DATA (DIESEL ENGINE
LIFT TRUCK) 4- 35
SERVICE DATA (GASOLINE ENGINE
LIFT TRUCK) 4- 32
TORQUE LIST 4- 37
SHIFTING GEAR (CLUTCH TYPE LIFT
TRUCK) 3- 21
STARTING AND INCHING ON INCLINE 3- 22
STARTING LIFT TRUCK OFF 3- 16
STRUCTURE AND STABILITY OF THE
LIFT TRUCK (TO PREVENT LIFT
TRUCK FROM TIPPING!) 2- 26
SUITABLE OIL 4- 14
<T>
TECHNICAL DATA 5- 2
TEMPORARY STOPPING AND
PARKING 3- 24
TOWING 2- 37
TRANSPORTATION 3- 33
TURNING 3- 23
<W>
WARRANTY AND SERVICE FOR NEW LIFT
TRUCK 1- 5
6-2
.
.
FG(D)10/18-20, FG(D)20/35-16 FORKLIFT TRUCK
Form No. AEB16E1-01
PRINTED IN JAPAN
01-05(00-1)02001

Aeb16e1 01

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Aeb16e1 01

Uploaded by

Copyright:

Available Formats

.

FOREWORD SAFETY INFORMATION

DIRECTION OF TRUCK FOREWORD

FOREWORD WARRANTY AND SERVICE FOR NEW LIFT TRUCK

WARRANTY AND SERVICE FOR NEW LIFT TRUCK

RUNNING IN NEW LIFT TRUCK FOREWORD

RUNNING IN NEW LIFT TRUCK

Idle the engine for 5 minutes after starting it up.

Avoid operation with heavy loads or at high speeds.

Unit Check items Remarks

FOREWORD LOCATION OF PLATES

APPLICABLE LIFT TRUCK SERIAL NO. LOCATION

LIFT TRUCK EMBOSSED SERIAL NO. LOCATION

LOCATION OF PLATES FOREWORD

EMBOSSED SERIAL NO. LOCATION

APPLICABLE LIFT TRUCK SERIAL NO.

SAFETY MANAGEMENT SAFETY

MAKE SAFETY PLANS BEFOREHAND

FOLLOW THE SAFETY RULES IN PLACE

ENSURE SAFETY AT THE WORKING AREA

WEAR SAFETY CLOTHES WHILE IN OPERATION

SAFETY SAFETY MANAGEMENT

KEEP THE OPERATOR'S COMPARTMENT CLEAN AND TIDY

REDUCE LOAD FOR LIFT TRUCKS WITH ATTACHMENT

DON'T REMOVE THE OVERHEAD GUARD AND BACKREST

ENGINE EXHAUST GAS IS POISONOUS

SAFETY MANAGEMENT SAFETY

FIRE IS STRICTLY PROHIBITED IN REFUELING

REMEMBER THE FOLLOWING JUST IN CASE

SAFETY SAFE TRAVEL

DON'T TRY TO OPERATE THE LIFT TRUCK FROM OUTSIDE

DON'T ALLOW A PASSENGER

SAFE TRAVEL SAFETY

BE SURE TO WEAR THE SAFETY SEAT BELT

CHECK THE SURROUNDINGS FOR SAFETY BEFORE STARTING UP THE ENGINE

CHECK AND ADJUST THE REARVIEW MIRROR AND LAMPS

SAFETY SAFE TRAVEL

MAKE A SAFETY CHECK BEFORE STARTING THE LIFT TRUCK

A SUDDEN SHIFT OF THE F-R LEVER IS DANGEROUS

BE ALWAYS CONSCIOUS OF SAFETY WHILE DRIVING

SAFE TRAVEL SAFETY

DO NOT DRIVE IN ON THE ROUGH GROUND

DRIVING ON A ROAD SHOULDER IS STRICTLY PROHIBITED

SAFETY SAFE TRAVEL

BE MINDFUL OF THE LIFT TRUCK'S MAX. HEIGHT AND WIDTH

SAFE TRAVEL SAFETY

WHEN DRIVING UP OR DOWN A SLOPE, EXERCISE EXTRA CARE

For safe travel on slopes.

WHEN MAKING A TURN, BE CAREFUL OF THE SWINGING TAIL

SAFETY SAFE TRAVEL

WHEN CARRYING A HIGH LOAD, USE A SIGNAL PERSON OR DRIVE BACKWARD

SAFE TRAVEL SAFETY

APPLY THE BRAKES CORRECTLY WHILE RUNNING

THE REQUIRED BRAKING DISTANCE DIFFERS DEPENDING ON THE ROAD CONDITIONS

SAFETY SAFE TRAVEL

FOLLOW THE STEPS FOR PARKING

PARK THE LIFT TRUCK IN A SAFE PLACE

DON'T USE A LIFT TRUCK WITH A DEFECT

SAFE TRAVEL SAFETY

DON'T USE A LIFT TRUCK TO TOW ANOTHER BROKEN-DOWN LIFT TRUCK

SAFETY LOADING OPERATIONS

Do not allow anyone except the signalperson in the working area.

DON'T GO UNDER THE LIFTED FORK